webb06 official build thread

[powerstroked08]

Man this really has me scratching my head! I just cant understand why a better intercooler would hinder performance, especially boost.

 

[bigrpowr]

Man this really has me scratching my head! I just cant understand why a better intercooler would hinder performance, especially boost.

it hasnt, to my knowledge affected anyone else, i know my silver truck gained 2+ psi of boost going to it from stock. it must have a blockage in it somewhere is all i can surmise. there's about 50 of those things out there with no issue that i am aware of. while i'm puzzled, i am happy he found the issue.

 

[powerstroked08]

it hasnt, to my knowledge affected anyone else, i know my silver truck gained 2+ psi of boost going to it from stock. it must have a blockage in it somewhere is all i can surmise. there's about 50 of those things out there with no issue that i am aware of. while i'm puzzled, i am happy he found the issue.

Yes I agree that the only thing I can think of is a blockage in it somewhere. But it would surprise me since of the QC you had on these. But either way I'm glad its up and running right!

 

[powerstroked08]

Is there a way to test for blocked tubes?

 

[webb06]

Is there a way to test for blocked tubes?

I don't have a way to do it. Like a way to test flow of it

 

[powerstroked08]

This may sound dumb but can you fill it most of the way up(almost to the top of the tubes)with cold water and then check the tube temperature with an infrared heat gun? Wouldn't the blocked tubes show up warm? Just thinking out loud.

 

[madman1234509]

You also changed gate settings at well? Are you sure it was the intercooler causing the issue and not the gate opening?

 

[Morgan@Midwest Diesel & Auto]

You could just cut the end tank off. I mean if it's bad it's bad. If you clean it out it could be tig welded back on. Should shed some light on what caused it.

 

[powerstroked08]

You could just cut the end tank off. I mean if it's bad it's bad. If you clean it out it could be tig welded back on. Should shed some light on what caused it.

Very true.

 

[webb06]

You also changed gate settings at well? Are you sure it was the intercooler causing the issue and not the gate opening?

Throughout all the testing today the boost supply for the gate was off. So there was no boost going to the gate to open it. Immediately after I swapped intercoolers boost was reading 52 on the factory sensor. On Dustin's harness I was seeing 56-57 so I have no doubt that boost is actually in the 56-57 area rather than 52.

Once I was done testing I hooked the wastegate back up and lost some boost. So I think the regulator is leaking air off. Haven't messed with that just yet

 

[webb06]

You could just cut the end tank off. I mean if it's bad it's bad. If you clean it out it could be tig welded back on. Should shed some light on what caused it.

I don't really see what could be obstructing it? I can look all the way down both tanks and cant see anything there

 

[Dzchey21]

You also changed gate settings at well? Are you sure it was the intercooler causing the issue and not the gate opening?

no we have data to back up the intercooler issue

Before the change we were seeing 53 psi PRE intercooler and 46 psi in the manifold

Now its seeing 58psi PRE turbo and 56 in the manifold, def something wrong with the intercooler, what it is i dunno.
I think part of the gate issues now is that the engine is seeing MORE air than it was before so now back pressure too has come up, but at least the turbos arent working so hard to not get all that nice air flow into the manifold

This is all monitoring with two identical sensors in each pipe, same thing with the atmospheric pressure, good hard data no guessing going on. Trust me the last thing i wanted to do was condem the intercooler but the math wasnt making sense. It was crazy too that atmo was making 35psi at times with the no limit intercooler, the restriction did some odd things

 

[B585Ford]

no we have data to back up the intercooler issue

Before the change we were seeing 53 psi PRE intercooler and 46 psi in the manifold

Now its seeing 58psi PRE turbo and 56 in the manifold, def something wrong with the intercooler, what it is i dunno.
I think part of the gate issues now is that the engine is seeing MORE air than it was before so now back pressure too has come up, but at least the turbos arent working so hard to not get all that nice air flow into the manifold

This is all monitoring with two identical sensors in each pipe, same thing with the atmospheric pressure, good hard data no guessing going on. Trust me the last thing i wanted to do was condem the intercooler but the math wasnt making sense. It was crazy too that atmo was making 35psi at times with the no limit intercooler, the restriction did some odd things

I am just trying to understand this, but where were you seeing the 58 PSI (? pre turbo)?

 

[Dzchey21]

I am just trying to understand this, but where were you seeing the 58 PSI (? pre turbo)?

luckily he had a bung welded in the hot pipe already so we put a sensor in it.. when i say we Webb did all the work, i was just taking his data and trying to figure out WTF was going on. Most trucks dont have this option. Mine included

 

[B585Ford]

luckily he had a bung welded in the hot pipe already so we put a sensor in it.. when i say we Webb did all the work, i was just taking his data and trying to figure out WTF was going on. Most trucks dont have this option. Mine included

If you don't mind, I just want to clarify because some day I hope to add fuel and do a little different arrangement on the turbos so the bung setup will be handy in case there are issues. The 58 PSI was in the hot pipe connecting the HP turbo to the IC, right? Thanks.

 

[Dzchey21]

correct, that was measuring right out of the high pressure turbo before it goes down and into the intercooler.

Post intercooler was measured in the manifold as it should be, i suppose if you wanted to get technical you could measure in the cold pipe and again in the intake, but if everything is ok there shouldnt be any loss.

From what i found asking around you should not have any more than 2psi drop across the intercooler and in the perfect world you loose 0 psi, but the gain in intake air temp drop is much better than the additional 2 psi of boost

 

[Dzchey21]

The only other thing i can think of that would cause the intercooler to get plugged would be a turbo failure putting oil in the intercooler, water/sludge combined (not sure what that would be from but i have seen in on machines) or something possibly wrong with the core or tank... too many things to go wrong

 

[blk350on20s]

Did you have this issue as well Dustin?

 

[B585Ford]

correct, that was measuring right out of the high pressure turbo before it goes down and into the intercooler.

Post intercooler was measured in the manifold as it should be, i suppose if you wanted to get technical you could measure in the cold pipe and again in the intake, but if everything is ok there shouldnt be any loss.

From what i found asking around you should not have any more than 2psi drop across the intercooler and in the perfect world you loose 0 psi, but the gain in intake air temp drop is much better than the additional 2 psi of boost

Thank you. That is very helpful.

 

[webb06]

It's a no limit hot side pipe. That's why it's got the bung. The intercooler has no oil or anything at all inside of it.