Teardown and Rebuild

[AH64ID]

7 minutes ago, TFaoro said:

Do you have a link to your info? I couldn't find anything on their site and I already closed the tab where I found it haha.

I don't know how much fuel this Ppump will move, but it's a lot. My Fass 95 can't keep up - drops from 36psi to 18, and I've only got the pump set at 360cc's. It'll flow 450....

 

I called and spoke to Baldwin directly. 

 

The good thing about high pressure is the fuel pump rating is at 0 psi. So at 36 psi it's not flowing 120 GPH (or whatever it's rated for), and you're likely okay with 90 GPH filters. 

[TFaoro]

1 hour ago, AH64ID said:

 

I called and spoke to Baldwin directly. 

 

The good thing about high pressure is the fuel pump rating is at 0 psi. So at 36 psi it's not flowing 120 GPH (or whatever it's rated for), and you're likely okay with 90 GPH filters. 

That's pretty ridiculous they don't have it somewhere in writing. If I want to compare specs and they don't have the information available, I would just rule it out.

[AH64ID]

4 minutes ago, TFaoro said:

That's pretty ridiculous they don't have it somewhere in writing. If I want to compare specs and they don't have the information available, I would just rule it out.

 

I found that I had to do a bit of calling to get information. 

 

For the most part people don't care about specs so there isn't much incentive for them to publish them. 

[TFaoro]

Lots done tonight. Started by getting the filters bolted up to the frame. I used two layers of inner tube to absorb some of the shock from the frame. 

Got the lines and the bracket hooked up

 

 

 

I ran the truck for a bit to make sure if any dust or contaminants weren't going to go through the new injectors. 

I then yanked all of the injectors. They looked absolutely horrible.... None of them look even remotely acceptable. 

Then I figured I might as well compression test it while I've got all of the injectors out. I was very happy to find all 6 were dead on the same compression at just under 400psi. 

 

Then the injectors went in.

 

 

 

 

I can say it idles waaaaay smoother than it did. The engine doesn't shake at all like it did. Also, the copper washers are noticeably thinner. Not sure if that does anything more than keep the spray within the bowl. 

They have a nice haze at idle, but we'll see how they are driving. Cleanup in the morning, then I'll see if I can't go break something. 

 

[notlimah]

Looks good man. Those injectors are from infinite performance right? 

[TFaoro]

On 9/30/2017 at 12:26 AM, notlimah said:

Looks good man. Those injectors are from infinite performance right? 

Correct, and they were pretty!!

 

Little update on them - I got to drive the truck for 30 min or so. The injectors are not any dirtier than the old ones, and probably even cleaner off idle. They do haze about the same as the others, but they don't make the engine shake around at idle.

I have not let the pump push all it can yet, but the EGTs and smoke are down while the boost is up. Almost 30psi out of the primary with a cracked boost gauge line. 

Fuel pressure stays up better with this filter setup and fuel lines. It's holding 4-5psi higher at WOT. 

I do have a couple issues - 1 the crossover tube O rings need replaced. (I expected this)

2  after the engine warms up it develops a slight miss. I'm thinking this is related to one of the injection lines not being seated when it's warmed up. I'll have to get it hot then crack all of the lines loose and tighten them back up. Hopefully that'll stop the shenanigans. 

[notlimah]

Sounds good. Really hoping you can get the truck up and running so she's reliable for you again! 

 

I think I'll end up going with injectors for IP as well, just going to have to talk to them about a more 'normal' size then what they seem accustomed to making haha!

[TFaoro]

On ‎10‎/‎1‎/‎2017 at 11:11 PM, notlimah said:

Sounds good. Really hoping you can get the truck up and running so she's reliable for you again! 

I'm going to try and get the miss fixed today, then bump the timing to the low / mid 20s. I think it's at 18 now.

 

On ‎10‎/‎1‎/‎2017 at 11:11 PM, notlimah said:

 

I think I'll end up going with injectors for IP as well, just going to have to talk to them about a more 'normal' size then what they seem accustomed to making haha!

I think Weston can make just about whatever you want. He even made an 8x.010 or 8x.011 for Wade and he seems to like them.

[Me78569]

@TFaoro curse you!!!! the tfaoro leaky line curse has migrated to my truck.    I should have never parked my truck close to yours.   

 

 

 

lines 5 and 4 have now been polished up,  we will see if I continue to leak diesel.

[TFaoro]

13 hours ago, Me78569 said:

@TFaoro curse you!!!! the tfaoro leaky line curse has migrated to my truck.    I should have never parked my truck close to yours.   

 

 

 

lines 5 and 4 have now been polished up,  we will see if I continue to leak diesel.

Lolololol  

That's what you get for being near it! I'm sure @trreeds will start leaking now that he was close to mine!

 

I personally have #6 dumping fuel.... the other 5 are sealed after new crossover tube O rings.

I'm 99.9% sure the line isn't sealing to the crossover tube since I pressurized the return system and nothing came out of the #6 area.

[trreed]

My truck already hates me.

[crf450ish]

On 9/27/2017 at 10:13 PM, TFaoro said:

Started building the fuel system tonight. 

I ordered 2 filter heads, a Donaldson water separator, Donaldson 3um filter, 10 ORB to 10 ORB adapter, a 3/8 pushloc to 10 ORB fitting and two 1/2 pushloc to 10 ORB fittings.

I started with a 7.5" wide piece of 3/16 AR plate, cut two sections, and butt welded them together. I then drilled the holes for the filter bases and where it'll mount to the frame (We'll get there)

Then it wouldn't be mine if I didn't brace it with some 1.5" x 1/4" strap.

Then I really braced it  - FYI it'll hold all 220lbs of me against the frame with 1 tight bolt, so two filters should be fine!

Here's where it mounts to the frame. Those were both existing holes, so no structural integrity taken out of the frame. (1/2in bolts BTW)

Here you can see where the fuel line will run from the pump into the filters. BTW the closest mount to the camera is the rear cab mount. 

Here you can see where the Fass is mounted. I'll make a new bracket for the A1000 when I order it. 

Here's the bases and the mount mounted to the frame. 

Mounted with the filters

Here's a shot of how low the filters hang. They should be very well protected by the frame and traction bar mount.

Last picture. Now some of you may think this thing is rusting apart, but I swear all of the rusty color on the cab is diesel mixed with road base! 

Those are some good looking hardwire welds on that bracket! ??

[TFaoro]

On ‎10‎/‎14‎/‎2017 at 2:16 PM, crf450ish said:

Those are some good looking hardwire welds on that bracket! ??

Thanks! I'll never claim to be the best welder, but usually they're pretty strong  

[TFaoro]

Still having missing issues. Working with @jlbayes and Seth Farrell to try and get things sorted out.

 

 

[jlbayes]

Burn it. I'll bring mine.

[Me78569]

need a third?

[trreed]

46 minutes ago, jlbayes said:

Burn it. I'll bring mine.

Best advice yet.

[TFaoro]

The pump was sent off to Farrell last week. 

I picked this up Friday. 2014 Ram 2500 quad cab short bed with a 50 gallon transferflow tank airbags with compressor with 32K on the clock. It'll be nice having something reliable, but don't worry the 2nd gen will still get love!

 

 

[Mopar1973Man]

Should have made that a new thread in the 4th gen area. Nice truck. Time to update your signature and garage...

 

Just make sure you get after that fuel filter and get ready to replace injectors in the future. If the grid heater light comes on while your driving you can bet you've got excessive return flow from the injectors. 

[Dieselfuture]

Look at you, all fancy. ... I'd like to get a new one with 4 doors but  can't afford it I don't think. Waiting on wife to get somewhere at her job then maybe if play my cards right never know. Just wish newer one's didn't have all the expensive problems they come with. But then again if I had money to buy one I wouldn't worry about fixing it, probably just pay someone to do it too. Nice color.