It is amazing how far the diesel performance industry has progressed in the last few years. Not too long ago, a diesel truck with just a chip, injectors, and a turbo upgrade was considered to have big horsepower. But as the industry has evolved and individuals have pushed for more and more power, diesel engine upgrades have changed a lot too. It used to be almost unheard of for people to upgrade their diesel engine's pistons, rods, and camshafts. These days there seems to be no shortage of diesel enthusiasts with fully built engines, dual injection pumps, and massive turbochargers.
Piston-Melting PowerFrank Fredrickson is one of those people that didn't intend to be a hardcore diesel performance enthusiast, but that's what he is now. He bought this '06 Dodge Cummins brand-new, and soon after taking ownership he installed a performance downloader. The power was great and Frank was really enjoying his new truck. That was until the number six piston melted down. The engine needed to be rebuilt and the dealer wouldn't warranty it because of the downloader. Frank was faced with the unpleasant prospect of paying several thousand dollars for a new engine himself. After much contemplation, he decided that if he was going to spend all that money on a new engine, he might as well build the engine for performance right from the start. Frank had always dreamed of building a high-horsepower truck anyway, and the mechanical failure just helped him to start the process quicker than he expected.
Critical FoundationFor the past few years Frank has been in regular contact with the staff of Industrial Injection, which had helped him with his other truck-a Cummins 12-valve Dodge. When the engine in his '06 Dodge needed to be rebuilt, he contacted the guys at Industrial for some help. One thing led to another, and the truck was dropped off at the Industrial Injection shop in Salt Lake City for a complete engine rebuild and a few other goodies. Industrial Injection pulled the engine and rebuilt the 5.9L common rail from scratch. No expense was spared in the buildup so that the finished product would be able to handle huge power. The rebuild included: HPC-coated pistons, billet pushrods, 12-valve connecting rods, a billet camshaft, heavy-duty valvesprings, studs, and a fire-ringed head. The rotating assembly was even balanced.
Dual CP3s, Injectors, and an Enormous TurboWith a fresh engine capable of handling much more fuel and air, Industrial Injection moved on to upgrading the fuel system. Again, no expense was spared and a second belt-driven CP3 injection pump and five-hole Dragon Flow injectors were bolted on. With almost twice as much injection potential, the stock fuel pump would have struggled to flow enough diesel, so a FASS 150/200 fuel pump and filter system were also installed. A Bully Dog Triple Dog downloader with a custom tune was uploaded to make sure all the mechanical components were being controlled properly. The last step of the build was to figure out a turbo system that would provide enough air for all the fuel. Industrial Injection's new handmade stainless steel exhaust manifold was installed along with a huge Phat Shaft 71 single turbo with an external wastegate. A Nitrous Express dual kit was also added to help the big turbo spool and create even more power. Obviously, the exhaust system needed some help as well, so one of Frank's buddies at Durango Muffler built a custom dual 5-inch stack kit.