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    Chasing down smokiness and lack of power

    My custom rebuild cost was around $12K, which included close to $2K for shipping from CA to WY and back. Justin charges $6.5K for a basic custom engine build. I had just about everything possible done, i.e. turbo rods & pistons, stronger head studs, his IP, injectors, cam, & fuel rail, etc...
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    Chasing down smokiness and lack of power

    My '91 F350 with the 7.3 IDI started emitting clouds of white smoke with an odor of diesel on startup, first running on 7 cyliders, then smoothing out after a few seconds. The smoke largely cleared up after a short time. However, it still blew out white smoke under throttle. I had added a Banks...
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    Unknown Radiator Support Bracket

    Nero, you are so correct. It is the "battery tray core support", according to an eBay listing I found using your suggestion. Not cheap; a rusty old piece of metal for $79, but worth it when desperately needed! Thanks for the prompt reply.
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    Unknown Radiator Support Bracket

    While Justin @ R&D IDI Performance builds the engine in my 1991 F350 7.3 IDI Diesel so it withstands all my upgrades for more power, I have been stripping the engine bay for a complete refurbishment. Unfortunately, I have only one of what I believe are two matching brackets that attach to the...
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    Banks Turbo Install - Turbo and Pressure Chamber Not Lining Up

    Oh, THAT brace.. Yeah, mine was quite tight, barely got it on; it was a struggle. I may have taken a rat tail file or dremel to its hole to finally get it on; not sure, but I remember it was a PITA. I hope you enjoy the end result as much as I have enjoyed mine. Trouble is, I tend to burn more...
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    Banks Turbo Install - Turbo and Pressure Chamber Not Lining Up

    Which tranny? I have the E4OD, custom built for me at Geezers Garage in Oregon, and the brace lined up perfectly. Regarding the firewall "modification", IMHO, they have us cut much more than needed out, but, yes, the downpipe needs all the clearance possible, but the driver's side didn't need so...
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    Banks Turbo Install - Turbo and Pressure Chamber Not Lining Up

    I installed the Sidewinder kit in my '91 F350 last year. After MANY struggles like yours, I finally ended up grinding the support foot on the casting, trying the fit, then grinding a little more, etc. until I finally got the casting installed. Maybe the '91 year is somewhat different than the...
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    7.3 idi turbo whistle

    Where is the whistle coming from? I installed a Banks Sidewinder kit on my '91 F350 7.3 IDI, and hear a whistle in the exhaust at idle, but that's all. The Sidewinder produces zero boost at idle, as designed.
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    Glow plug troubles

    The glow plug controller 12 V source goes through a big connector in the harness near the passenger side head, and is protected with fusible links buried in the harness next to the passenger-side battery. The pins in mine developed corrosion, creating resistance. My short term fix was to add...
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    Glow plug troubles

    Another vote for wires. The glow plug controller wires and the connector buried in the harness have caused many an IDI to fail to start as they age. I have a 1991 F350 Lariat Crew Cab, and I found high resistance in the connector that is in the middle of the harness, feeding voltage to the...
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    Ignition Switch RUN terminal wire R/LG always hot

    Well, I just opened up my harness, pulled out the unused glow plug wires to the old relay location, anf found to my delight that the ignition RUN wire and Warning light wire are just the right length to reach the new location on the passenger fender plate. So, maybe I should consider pulling...
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    Ignition Switch RUN terminal wire R/LG always hot

    I've been doing some number crunching on the glow plug wires. I had 2 factory 10 gauge wires with 14 Gauge fusible links in them. A 14 gauge fusible link is rated at 32 amps, so that suggests to me that a total of 64 amps is the maximum the factory wiring can handle, much less than what I have...
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    Ignition Switch RUN terminal wire R/LG always hot

    I have performed a GlowPlugWire-ectomy in prep for moving the relay onto the passenger fender. The plan is the use 4 AWG wire to and from the relay, one cable only to the rear of the engine, tied to the glow plug wires. I've read the glow plugs can draw 200 amps, and Philip1 (above) ended up...
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    Ignition Switch RUN terminal wire R/LG always hot

    Ah, that clears up a mystery, as to why on the back of the manifold. My experience tells me that items are mounted on the manifold for either vacuum or coolant. I gather it's still there on the 7.3 because "that's the way we've always done it", and "that's where the mounting holes are". Wow. Two...
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    Ignition Switch RUN terminal wire R/LG always hot

    laserjack, I see you have the Banks turbo. I received mine on Friday, and it will be the next project after I take care of this current issue. I'm wondering if I should move my relay/controller like you did. I have not seen one of these trucks with the Banks Sidewinder installed, but I have to...
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    Ignition Switch RUN terminal wire R/LG always hot

    I have read that the glow plugs can draw up to 200 amps, but laserjack suggests a 150 or 175 amp fuse will suffice. I'm thinking he may know from experience. How many amps do the glow plugs draw? I'd test the draw at my relay, but it's dead. I'm heading to the parts store to get a new relay, and...
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    Ignition Switch RUN terminal wire R/LG always hot

    Thanks for the tips. BTW, I had replaced those glow plug relay feed wires so many years ago, I had pretty well forgotten about it. I'm wondering what to replace them with so I don't go through this again. I thought AWG 10 automotive wire would be sufficient. Do others have this problem with...
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    Ignition Switch RUN terminal wire R/LG always hot

    To all who posted, a big hearty Thank You! I finally found the culprit, in the harness right where Franklin2 suggested. One of the glow plug wires feeding the relay had gotten hot enough to melt insulation on itself and a blue wire next to it, and I suspect the blue wire is the FSS solenoid...
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    Ignition Switch RUN terminal wire R/LG always hot

    I replaced the switch down toward the bottom of the steering column, but I have never tried it, because the R/LG wire (RUN) should not have 12 volts on it when the connector is not connected to the ignition switch. The wire next to it, BR/PNK (I think), is also sitting at 12 volts
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    Ignition Switch RUN terminal wire R/LG always hot

    A real mystery. My 1991 F350 7.3 IDI wouldn't turn off with the key, so I did the usual and pulled the FSS wire to kill it. I replaced the Ignition switch and checked the actuator rod. I checked voltages on the switch and found the RUN R/LG wire was hot. This wire is supposed to get voltage from...

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