1999 power stroke engine swap options.

Farmer Rock

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In case you're wondering, this is in the IDI section for a reason.
Backstory -
I bought this e99 7.3psd in April, really liked it and enjoyed the power. However, I have had a few electrical issues.
I'm in the process of a cab swap,
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and I really dislike how over complicated this truck is as far as wiring goes. It seems like it was built around the wiring, and there's no way to change that with the power stroke in place
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...so it's not in place anymore,lol.
I was originally thinking a dt360/466 swap, but there is that little part of me that has always wanted to build up an idit.
I have even thought about a 3208 or 9.0 v8 just to be different.
I feel like the IDI would be the easiest to swap because of the physical similarities to the power stroke.
I plan on keeping the zf6 btw.
The power stroke had good get up and go with a gold chip that came with it. I'd guess it to be a 50hp tune.
I would be extremely happy if that same HP level could be achieved with an IDI, or any mechanical motor for that matter.
This is a budget build, but I want to do it right either way.
I'm looking for opinions on this, as well as practical HP levels while staying reliable.
I don't need anything crazy, it's a work truck, but I just don't like all the failure points of the power stroke wiring, which is unfortunate because it's a good motor.thanks


Rock
 

Farmer Rock

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“Welcome back” rock. You can reliably make 7.3 psd numbers no problem with IDIT components and build. Budget may be a different story as that’s subjective to the person.
Thanks, I wondered to the dark side for a while,lol.
So, as much as I played with IDIs, I never actually improved the stock power levels like I always wanted to. I'm thinking around 250hp is a realistic goal?
Let me ask this, if I find a factory turbo motor, is this achievable by just upgrading the IP, injectors, and adding an intercooler since this 99 has one already? Of course, I'll have to stud it, but besides that, does this seem reasonable?
I've also got that Garret wg turbo from the psd I may use if I need more boost.


Rock
 

hacked89

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Thanks, I wondered to the dark side for a while,lol.
So, as much as I played with IDIs, I never actually improved the stock power levels like I always wanted to. I'm thinking around 250hp is a realistic goal?
Let me ask this, if I find a factory turbo motor, is this achievable by just upgrading the IP, injectors, and adding an intercooler since this 99 has one already? Of course, I'll have to stud it, but besides that, does this seem reasonable?
I've also got that Garret wg turbo from the psd I may use if I need more boost.


Rock
Yes, a guy in Jersey did that and was over 300+ HP at the crank on the dyno with a 90cc pump. I have a truck Im finishing with a 145cc pump that will likely send the NA rods into orbit.

This is his mod list:
Sleeved Turbo pistons and rods Total seal rings Arp studs R&D cam 90cc R&D pump R&D intake and exhaust manifolds Comp cam valvesprings Stock compression Turbo: hx35/40hybrid R&D downpipe
 

Farmer Rock

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Yes, a guy in Jersey did that and was over 300+ HP at the crank on the dyno with a 90cc pump. I have a truck Im finishing with a 145cc pump that will likely send the NA rods into orbit.

This is his mod list:
Sleeved Turbo pistons and rods Total seal rings Arp studs R&D cam 90cc R&D pump R&D intake and exhaust manifolds Comp cam valvesprings Stock compression Turbo: hx35/40hybrid R&D downpipe
So if you had to make a ball park guess, what do you figure that would set me back?
I have to weigh out different engines, but the IDI seems like the most economical choice.





Rock
 

hacked89

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So if you had to make a ball park guess, what do you figure that would set me back?
I have to weigh out different engines, but the IDI seems like the most economical choice.





Rock
Most cost efficient way is if you found a good running IDIT, wish you luck cause I haven’t seen any in PA, then just price out an IP and injectors from a vendor you like.
 

hacked89

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Not to say you can’t run a turbo NA but once you are in the 300s of HP you are getting towards the less safe zone
 

u2slow

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IIRC, the zf6/idi isn't a slam dunk like a zf5. Needs a custom adapter or something because the factory spacer was done away with on the 99+ PSD.
 

IDIBRONCO

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I'm thinking around 250hp is a realistic goal?
Easily. It also depends on whether you're talking 250 at the flywheel, or the rear wheels.
Needs a custom adapter or something because the factory spacer was done away with on the 99+ PSD.
IIRC, it's still there for a spacer, but it's no longer an adapter plate.
Let me ask this, if I find a factory turbo motor, is this achievable by just upgrading the IP, injectors, and adding an intercooler since this 99 has one already?
When he was still active on here, Macrobb said that he was making 250HP by maxing out a stock Turbo pump and adjusting his wastegate to get the max boost out of his Factory Turbo.
Not to say you can’t run a turbo NA but once you are in the 300s of HP you are getting towards the less safe zone
That's wheel HP. At the flywheel, you're still fine.
 

hacked89

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Easily. It also depends on whether you're talking 250 at the flywheel, or the rear wheels.

IIRC, it's still there for a spacer, but it's no longer an adapter plate.

When he was still active on here, Macrobb said that he was making 250HP by maxing out a stock Turbo pump and adjusting his wastegate to get the max boost out of his Factory Turbo.

That's wheel HP. At the flywheel, you're still fine.

The 90cc truck I was referencing did 269hp/552tq at the wheels. I know Justin is the one who proposed the “400hp” on NA rods number but how long did that last in his bronco? If rock went 110cc he can easily be in the 300s at the wheels. Not sure how long that would last NA. Maybe a long time? Justin had said the rods were slowly bending over time.
 

The_Josh_Bear

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This is his mod list:
Sleeved Turbo pistons and rods Total seal rings Arp studs R&D cam 90cc R&D pump R&D intake and exhaust manifolds Comp cam valvesprings Stock compression Turbo: hx35/40hybrid R&D downpipe =269hp/552tq at the wheels
Yeah welcome back, Rock! :fight:

IMHO you can get 90%+ of these results with far less coin invested. Maybe the turbo was cheap(usually not), all depends on that person and chinese/used vs. new, etc. But outside of that the rest can be pricey.

Since you asked about a budget build but also doing it "right", you need:

Studs, Wes has another USA vendor now that's cheaper than ARP because ARP can't keep them in stock
6.9 coolant mod
90+cc IP
DIY charge air cooling
(pretty cheap for what it does)
Weld or get an up-pipe kit to seal that dang thing like it should have been!
And then if you have an extra $1,000... drop in turbo upgrade from Wes or Justin. (Stage 1? I think)

I'm all for the cam, but a cam also means valve springs which is more money. If I ever build a 7.3 it'll be with Russ's cam, FYI.

I like the way @Macrobb would do engine builds. It's not the "right" way, but basically he would compression test it, and if it worked, just send it. He didn't spend 2 years building an engine. He drove it the 2 years and then some! :) So maybe this isn't the best advice but "budget" and "build engine right" aren't easy to put into the same sentence.

BTW you went to the dark side because IDI's were too expensive to maintain didn't you? Then decided to do a frame-off resto PSD so you can IDI swap it?? :drunk: :rotflmao:popcorn
 

Farmer Rock

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Yeah welcome back, Rock! :fight:

IMHO you can get 90%+ of these results with far less coin invested. Maybe the turbo was cheap(usually not), all depends on that person and chinese/used vs. new, etc. But outside of that the rest can be pricey.

Since you asked about a budget build but also doing it "right", you need:

Studs, Wes has another USA vendor now that's cheaper than ARP because ARP can't keep them in stock
6.9 coolant mod
90+cc IP
DIY charge air cooling
(pretty cheap for what it does)
Weld or get an up-pipe kit to seal that dang thing like it should have been!
And then if you have an extra $1,000... drop in turbo upgrade from Wes or Justin. (Stage 1? I think)

I'm all for the cam, but a cam also means valve springs which is more money. If I ever build a 7.3 it'll be with Russ's cam, FYI.

I like the way @Macrobb would do engine builds. It's not the "right" way, but basically he would compression test it, and if it worked, just send it. He didn't spend 2 years building an engine. He drove it the 2 years and then some! :) So maybe this isn't the best advice but "budget" and "build engine right" aren't easy to put into the same sentence.

BTW you went to the dark side because IDI's were too expensive to maintain didn't you? Then decided to do a frame-off resto PSD so you can IDI swap it?? :drunk: :rotflmao:popcorn
You really got me laughing on that last part,lol...
I sold all my IDIs and parts because the truck it self wasn't heavy enough for my work. The IDIs did ok, but the zf5s and 3.55 gears didn't.
I bought the psd, absolutely loved the truck, but the more I got into it, I realized it has way too many failure points.
Now that the cab is off, I just can't put the psd back. I want a mechanical engine in that chassis. Whether it be an idit or dt, it won't be a psd.
I'm leaning towards the IDI, especially since I don't want crazy power, just reliable.
Then again, shoe horning a dt466 in there would be something else,lol
I really have to sit down and compare them in terms of $$$.
Which probably means idit


Rock
 

hacked89

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DT466 street driveable F series swap is a test of a man. Many have fallen to it. There’s one on YouTube currently getting closer but still a ways to go. They are currently 4 years into it.
 

Farmer Rock

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DT466 street driveable F series swap is a test of a man. Many have fallen to it. There’s one on YouTube currently getting closer but still a ways to go. They are currently 4 years into it.
.... CHALLENGE ACCEPTED,LOL
seriously though, I've been putting some thought into this.
I've been researching what little I can find on a 466 swap.
I know it will be an undertaking, however, I have always thought it would be an amazing combination in a sd.
From my point of view, there is a bare frame and axles in the garage, I have a cc for it, all the parts. So if I'm gonna swap in an oversized engine, now's the time.
I realize it will be the little pieces of the puzzle that hold things up like any swap. I'm already figuring I'll have to fab up a big dog house, and possibly a dash depending on how big.
But as far as the mechanics/engineering of it go,
Motor mounts

Tranny adapter, clutch, and hydraulics

Adjust drive shaft length

Power steering/hydro boost

Electrical,gauges

Cooling system.
I honestly feel that sitting the engine back in a dog house will solve a lot of potential problems.
This is obviously turning into a long term project at this point, but hey.... it's all or nothing,lol
I'm tired of seeing Cummins swaps, and as much as I'd like an IDI, I may as well swap in a inline motor at this point.
I'll post this up in the conversion forum next.
I have way to much thinking time running a welder all day....lol


Rock
 

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