7.3 powerstroke mechanical conversion

ReapersTrucking

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Bought a 94' 7.3 powerstroke dirt cheap, low original miles, manual. Electrical is all tore up, converting it to mechanical injection with a 94 idi pump and housing. Will be doing machining to retro fit injectors into heads, Was wondering if anyone knows if the injection pump gear on an idi is similar pattern to the cam gear on a powerstroke? Im guessing i'll have to get a new gear made to match it but if they happen to be the same will make the process much more simple to retro fit the pump housing. Not looking for disclaimers or getting told the build won't work. To have the machine work done will end up costing way less than the $22k for the mechanical convesion that's on the market, Thanks - Joe
 

YJMike92

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I can't answer your question, but please keep us posted. This sounds interesting.
 

aggiediesel01

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Hypermax engineering has done something along these lines with a mechanically injected direct injected Powerstroke and they sell the parts too. I suggest you research this idea in the threads of this and other forums to see if this is really a project you are ready to take on. I thought it was around 12k instead of 20k but maybe it’s been that long since I saw their system. Your proposed idea is really quite a complex engineering task not generally suited for the weekend warrior with a roll of duct tape and bailing wire, likely even someone with access to a complete machine/fab shop. As they are, the two engines are completely uncompatible as far as fuel injection systems and combustion cycles are concerned. One architecture is designed around indirect injection and the other is direct injection. These two systems were engineered for different injection timing curves and combustion chamber designs. You can get as creative as you have imagination, patience, and financing for but ultimately there is likely not enough experience in these inter-webs to help you combine these two architectures into a successful endeavor if you don’t already have extensive engine design experience already. It would be far less expensive and headache and way more successful for everyone involved to help you fix every single possible problem with your existing electrical system than to try to help create a idi/di hybrid.

Sorry to rain on your parade but that’s quite the reality with these two old engine designs, there’s not much enthusiasm for radical new ideas anymore. Most of the experience and effort you will find here and on other forums is geared towards helping folks fix and maintain what they have. There is not much support or willing knowledge for creating a new beast. The enthusiasm for creating and supporting new products and designs for the diesel market is found with the newer engine architectures. Each of these engines have been pushed to their limits over the past 20-30 years and the knowledge base is pretty well established now even though the last 5-7 years of 7.3 idi fuel system development has been turned on its head by some determined enthusiasts.

Don’t get me wrong, we all love to live vicariously through someone else’s projects, to spend their money on shiny cool and unique toys and to watch what comes of it. But unless you yourself have the intestinal fortitude to read engineering texts and diesel engine design theory to figure out all of it on your own when you can’t find an internet guru to answer your questions. Then it might be wise to consider the path more traveled.
 

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