Twin Turbo Build for 5.9 Common Rail
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Thread: Twin Turbo Build for 5.9 Common Rail

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    Supporting Member khaoskustoms's Avatar
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    Default Twin Turbo Build for 5.9 Common Rail

    I'm going to be putting twins on my girlfriends truck right away. Turbos are going to be a Borgwarner S300 with the 60mm compressor, 68mm turbine and .91 divided T4 non gated housing over an SX480, 80mm compressor and 96mm turbine, divided 1.32 T6 housing. Steed Speed T4 Manifold with a Turbonetics RG45 external wastegate. Her truck had a Industrial Injection Silver Bullet 66/74/14cm turbo with 120hp injectors, Colt Stage 2 cam and dual injection pumps. Going to up the injectors from 120's to 200's. I'll get some pics up as I go. I'm hoping for 800hp on fuel. Oh, it's a 2006 Dodge 2500 SLT with only 120,000kms on it.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Supporting Member khaoskustoms's Avatar
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    Picture of the truck

    ImageUploadedByTapatalk1368552396.921603.jpg

    Waste gate

    ImageUploadedByTapatalk1368552431.835574.jpg

    Should have pics of the turbos soon.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Is that the one that was in the shop behind your Dakota last fall, I had it in my head it was blue, i don't know why.
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    How much power are you shooting for ultimately?

    How hot is the stage 2 cam, and what does it make the engine sound like?

    What the heck is she going to do for a trans?

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    Johnny C - KK4HAN - TLCA# 17825
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    Quote Originally Posted by lawnboy View Post
    Is that the one that was in the shop behind your Dakota last fall, I had it in my head it was blue, i don't know why.
    I don't remember what truck you saw. Her truck has been in storage the last year and a half. It went on the backburner so I could finish my Dakota. Now that the Dakota is out of the picture for the summer, time to get her's done.

    Quote Originally Posted by nexxussian View Post
    How much power are you shooting for ultimately?

    How hot is the stage 2 cam, and what does it make the engine sound like?

    What the heck is she going to do for a trans?
    800hp on fuel at a cool 1200-1400 degrees egt. Stage 2 is basically just a re-grind of the exhaust lobes. It doesn't really change the sound too much. I've found that the turbo selection changes sound more then anything. The trans in it now is something I've put together with DTT parts. DTT valvebody and converter, red alto clutches and a billet input shaft. I'm prepared to put in a different trans if this one decides it doesn't like the power I'll be putting through it lol.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Quote Originally Posted by khaoskustoms View Post
    800hp on fuel at a cool 1200-1400 degrees egt.
    More than I'm looking for.

    Quote Originally Posted by khaoskustoms View Post
    Stage 2 is basically just a re-grind of the exhaust lobes. It doesn't really change the sound too much. I've found that the turbo selection changes sound more then anything.
    Thank you.

    I have been contemplating an automotive swap for some time, the current "Cummins Cars" thread made me invest more thought in what I would like to build ( older Packard 4 door with the long nose and the dual side mounts) with 400-425 hp at the flywheel (heavy car) and boat loads of torque ( hence diesel, 'cause it's a heavy car ).

    My point asking about sound is I want to keep the rattle at idle and cruise (low power) to a minimum (all the better to sneak up on them ).

    There used to be a Dodge Cummins that drove by my house on a semi regular basis, it was quick and sounded more like a twin turbo Porche, (badging and turbo chirp through the exhaust gave it away).

    I expect it was commonrail (right year range, and should help with rattle reduction) but beyond that I have no idea as I never saw it parked.

    I know that's a ton of diesel HP for a car, but I'm expecting an empty weight (wet) of between 6,500Lb and 10,000Lb (did I mention it was going to be heavy? )

    I was thinking double overdrive Allison with a narrowed AAM1150 out back (jumbo 4link, air ride, discs and front suspension to match).

    Sorry about the hijack, it's just a flaky idea I've had rattling around in the back of my mind, pops and I always build smaller, lighter cars and trucks, just once I want to build something big, but it needs the power to be as rowdy as the rest of our builds.
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    Do it, that would be super sweet.

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    Quote Originally Posted by nexxussian View Post
    More than I'm looking for.



    Thank you.

    I have been contemplating an automotive swap for some time, the current "Cummins Cars" thread made me invest more thought in what I would like to build ( older Packard 4 door with the long nose and the dual side mounts) with 400-425 hp at the flywheel (heavy car) and boat loads of torque ( hence diesel, 'cause it's a heavy car ).

    My point asking about sound is I want to keep the rattle at idle and cruise (low power) to a minimum (all the better to sneak up on them ).

    There used to be a Dodge Cummins that drove by my house on a semi regular basis, it was quick and sounded more like a twin turbo Porche, (badging and turbo chirp through the exhaust gave it away).

    I expect it was commonrail (right year range, and should help with rattle reduction) but beyond that I have no idea as I never saw it parked.

    I know that's a ton of diesel HP for a car, but I'm expecting an empty weight (wet) of between 6,500Lb and 10,000Lb (did I mention it was going to be heavy? )

    I was thinking double overdrive Allison with a narrowed AAM1150 out back (jumbo 4link, air ride, discs and front suspension to match).

    Sorry about the hijack, it's just a flaky idea I've had rattling around in the back of my mind, pops and I always build smaller, lighter cars and trucks, just once I want to build something big, but it needs the power to be as rowdy as the rest of our builds.
    Commonrail's are alot quiter and smoother then the old mechanical 12v's. The power you want would be easy to make with a small 62mm single turbo, 50hp injectors and either a downloadable tuner or just a pressure box if you don't get the OBDII hooked up on your swap.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Those look sexy... how long til they are mounted?
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    Quote Originally Posted by AcIdBuRn02ZTS View Post
    Those look sexy... how long til they are mounted?
    Awhile yet. The steed speed manifold is still 2-3 weeks away.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    I heard EFI live makes those 5.9's spool and drive like a dream!
    Should be a lighting quick spool with the right tune!
    '82 300D Bosch MW turned up some, 3" turbo back, A/W intercooler, HX30
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    Quote Originally Posted by mfsuper90 View Post
    I heard EFI live makes those 5.9's spool and drive like a dream!
    Should be a lighting quick spool with the right tune!
    Yes, it really changed the driveability of the truck when it still had the single 66mm turbo.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    60mm over 80mm? That's quite a bit bigger spread than I'm used to! In the dmax world its usually s366 over s483 or stock turbo (~61mm) over s475. Isn't the stock he351cw a 60mm turbo?

    After seeing a billet output shaft break on a truck with considerably less power than you're planning on, I wouldn't put amy faith at all in a stock output shaft lasting more than a couple wot runs. I'm honestly surprised it didn't let go with the s366! But you're right, a good efi live tune makes a smarty look like child's play! Its amazing how good tuning wakes them up!

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    drat...I knew I forgot to look at something when I was there this afternoon.

    looking forward to this build...try to hold up something to give scale to those turbo's...they are likely much bigger than we think.
    currently modding an 86' m-1010 cucv ambulance,with factory 14-bolt/detroit in back and an open 60 in front.lifted 6 inches,running 37's on 17 x 8's.now swappimg in a mild 6bt,and an nvg-4500/np205 combo.hope to have it running by fall.
    link to engine build... http://www.4btswaps.com/forum/showth...n-engine-build...

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    So I finally got this project mostly finished. Turbos are mounted on the truck and I have gone for a test drive with it. All I can say is OMG!!! This truck spools so fast and pulls so strong! Can't wait to get some tuning done on it and really see what it is capable of.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Gotta have pictures and specs of what you ended up doing.
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    I second that^^
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    Just curious if the girlfriend is an avid fellow hot rodder and speed junky or more of a passive observer?
    Please, READ STICKIES at top of forum sections!

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    Here's some pics of what I did for twins. Fairly simple setup using two box stock borgwarner turbos. A 60x68 .91 T4 S300 turbo as the secondary and a 80x96 1.32 T6 S400 turbo as the primary. Hot side piping is a little unconventional, and that is all I'm allowed to say about that for now. 5" downpipe into 5" magnaflow duals. 5" intake into an AFE air filter. Upgraded the injectors from DDP120's to Flux 4's which are rated at 200hp. Upgraded the CP3's with a 42% over II Dmax cp3 on top and the stock dodge pump on the bottom. Truck already has a mildly built engine with dual piston oil squirters and a colt stage 2 cam. I am currently writing my own EFI Live tune for it and so far its going well. Boost comes on at 1500rpm and makes 20psi by 1800rpm. I've seen total boost at 75psi with the primary makeing 40-45 psi of that. I still have more wastegate tuning to do and more EFI tuning. Tonight is going to be the first time I get to drive it home. Should be fun.
    Attached Images Attached Images
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Some more pics.
    Attached Images Attached Images
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Pretty tight under there, that had to take some work to make that all fit. Nice work.

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    The 480 fit pretty well in a close to stock 3rd gen location. Just had to grind the top of the engine mount a little to clear the compressor cover. Trimmed the batt box a little as well and the charge pipe fit nicely too.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Is that external wastegate to limit total boost or flow between turbos?

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    Quote Originally Posted by Drifter View Post
    Is that external wastegate to limit total boost or flow between turbos?
    Mainly control flow between turbos. On diesel alone I shouldn't exceed the capabilities of the S480's turbine and housing flow.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    Quote Originally Posted by JimmieD View Post
    Just curious if the girlfriend is an avid fellow hot rodder and speed junky or more of a passive observer?
    When I first met her, her truck made more power then mine lol.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    That's cool, I can't even get my wife to drive, care that I supped up her jeep when I rebuilt it, or even wash it.

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    Kinda surprised NASA hasn't knocked on your door.. When you got time can you make me a transporter like on Star Trek?

    Nice job!
    It will never be really finished 1965 GMC 1/2 TON 4X4- 4BT-M5R2 Divorced Rockwell Transfer Case. Dana 44 Front and Rear. 3200 Gov. Spring. TDC Fuel Pin. P/S -PB. On 33X10.50 X15 M/S. Rancho 9000

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    Quote Originally Posted by things View Post
    Kinda surprised NASA hasn't knocked on your door.. When you got time can you make me a transporter like on Star Trek?

    Nice job!
    Lol, Sure.

    Starting to get the tuning dialed in. Trucks making 80psi boost with EGT's in the 1600 degree range at WOT. Right now I'm working on a max effort tune, once that is done I will dial it back and write multiple similar tunes with less and less power all controlled by a 5 position rotary switch. So tune 1 would be her lowest power, maybe even the "valet" tune, then the tunes would go up in power one click at a time. I also have water injection for this engine as well, but won't be using that untill I am happy with the final tunes.
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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