6.0L Banjo Bolt Mod Part II - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 37 (permalink) Old 07-30-2005, 07:25 PM Thread Starter
 
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Lightbulb 6.0L Banjo Bolt Mod Part II

There are many ways of doing this MOD. Some might have a "remove less things" way. I personally like to work COMFORTABLE, meaning I like to get to the part without having to bust my knuckles, nor pushing stuff oout of the way.


Here is what your Ba:njo Bolts should look like after the Mod:
http://img94.imageshack.us/img94/9416/dscn20071fy.jpg
http://img94.imageshack.us/img94/9988/dscn20088yb.jpg


1.) Make sure you Truck is Cool.
2.) Open Radiator Resv. Cap in case off pressure still being in the system.
3.) remove Air Filter box completely, you will need a flat screw driver so you can disconnect the rubber hose that attaches to your turbo, disconnect the MASS sensor plug, and the useless Air fill restrictor sensor. Now the Air filter box is ready to come out.
4.) Remove the 1 3/4" coolant line that runs for the coolant Resv. to the Radiator.
5.) Remome your CAC Tube ( The one that clamps on to the intake elbow on the top of your engine and runs down into your inter cooler ).
6.)I removed my top Radiator hose.
7.) Removed the electrical plug to my Engine Cooling Fan.
8.) Removed the shroud surrounding the the fan, and the fan itself from the engine.( Some have done it wihout this step! )
9.) Once the shroud and fan come up, WOW! You can see your motor!
10.) look for the bolt on each head, they cannot be missed! they have a metal fuel line running into each one, and the bolt feeds the head from the front.
11.) Remove a bolt at a time, I would recommend ordering the bolts & copper washer from IH before starting the project so they are already pre-drilled and ready to swap out.

12.) here is where you just do the Banjo bolt mod, or you opt to go with larger fuel lines, and talk to DJ about his Fuel Pressure Xcellarator. To bump up the pressure from a measly 40psi stock to 100psi of fuel pressure. Since everything is already in the front and visible, now would be the proper time for these upgrades.

13.) If you just want the Banjo Bolt done, repeat the step backwards to start putting back on your fan & shroud, and the radiator hose etc.

If this is not sufficient enough information, or you might have qeustions on the mod, feel fee to PM ME at anytime!

-X
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post #2 of 37 (permalink) Old 07-30-2005, 07:36 PM
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I want to do this mod today, even thou I don't have the washers or bolts yet. (I ordered them on Wednesday) issed:
Do you think I will have a problem with leaks?
Does DJ have his fuel reg mod available yet? And is the mod done directly to the 2nd fuel filter/regulator? :bow:
:thanks:
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post #3 of 37 (permalink) Old 07-30-2005, 08:15 PM Thread Starter
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Quote:
Originally Posted by Extended Power
I want to do this mod today, even thou I don't have the washers or bolts yet. (I ordered them on Wednesday) issed:
Do you think I will have a problem with leaks?
Does DJ have his fuel reg mod available yet? And is the mod done directly to the 2nd fuel filter/regulator? :bow:
:thanks:
The Fuel Pressure Excellarator is just a bolt-on replacement to your Stock fuel pressure regulator, I beleive it's made of billet though, very nice looking, I'm the one who got screwed with the Guinea pig looking one! !!

:Thumbup:

Patience! It's worth it!

-X
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post #4 of 37 (permalink) Old 07-30-2005, 08:25 PM
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Will he be selling bigger lines with the regulator?
I forgot to ask that in my e-mails to him.
Also...any new info on a release date ?

I'm really, really trying to be patient.....I just suck at it...
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post #5 of 37 (permalink) Old 07-30-2005, 08:29 PM
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Choke,

You didn't specify anything in regard to the mods to the banjos themselves. Here is what I've done, others may do it differently...

There are 2 holes in the banjo fitting from the factory. They are approximately .120". I drilled those out to .144" first, then added 2 additional holes at 90 angles from the factory holes...also .144". NOTE: These can probably be drilled even larger, but I don't believe that it's necessary and it could hurt the integrity of the bolt. Remember, you still have to be able to reinstall and tighten the bolt...don't take too much material out!

After drilling the side holes, I drilled the center large hole out to .250" all the way passed the 4 side holes. I do this last because it helps to remove the internal burs from drilling the side holes.

Finally, using a dremel tool, lightly chamfer all 4 side holes. This removes any burs and also smoothes the entry into the hole.

Wash the banjo bolt THOROUGHLY to make sure that there are NO chips or debris before reinstalling.

Hope that helps.

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post #6 of 37 (permalink) Old 07-30-2005, 08:34 PM
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Quote:
Originally Posted by Choke_On_My_Smoke
The Fuel Pressure Excellarator is just a bolt-on replacement to your Stock fuel pressure regulator, I beleive it's made of billet though, very nice looking, I'm the one who got screwed with the Guinea pig looking one! !!

:Thumbup:

Patience! It's worth it!

-X
on the guinnea pig deal! It's usually us business owners that have the crappy looking test stuff.

I've never talked to DJ, but I was under the impression that he wasn't modifying/replacing the regulator. I thought his mods were to the pump itself.

Hopefully his piece and mine don't look too much alike, I've been working on a replacement regulator fitting as well...wouldn't want to be accused of copying anyone. Big difference is that mine isn't intended to be a standalone mod, it will be part of a complete fuel system setup like we do for the 7.3L trucks. Either way, more power to you and DJ and everyone else that's trying to make the 6.0s scream!

Dennis Schroeder - Co-Owner of Strictly Diesel
Strictly Diesel Webstore / [email protected]
LIKE US on FACEBOOK! / Check Us Out on YOUTUBE!
Race Truck :: 6050# / 11.31 @ 120mph / Best 60' of 1.56 ... with "Built" Race Engine (Fuel Only!)
Race Truck :: 5980# / 10.965 @ 124mph / Best 60' of 1.54 ... with "Built" Race Engine (Nitrous)
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post #7 of 37 (permalink) Old 07-30-2005, 08:39 PM Thread Starter
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Quote:
Originally Posted by ITPDiesel
Choke,

You didn't specify anything in regard to the mods to the banjos themselves. Here is what I've done, others may do it differently...

There are 2 holes in the banjo fitting from the factory. They are approximately .120". I drilled those out to .144" first, then added 2 additional holes at 90 angles from the factory holes...also .144". NOTE: These can probably be drilled even larger, but I don't believe that it's necessary and it could hurt the integrity of the bolt. Remember, you still have to be able to reinstall and tighten the bolt...don't take too much material out!

After drilling the side holes, I drilled the center large hole out to .250" all the way passed the 4 side holes. I do this last because it helps to remove the internal burs from drilling the side holes.

Finally, using a dremel tool, lightly chamfer all 4 side holes. This removes any burs and also smoothes the entry into the hole.

Wash the banjo bolt THOROUGHLY to make sure that there are NO chips or debris before reinstalling.

Hope that helps.
Yeah I have the pics of the bolts drilled and how to do it in the "6.0L Banjo Bolt Mod Part I"


thanks though!
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post #8 of 37 (permalink) Old 07-30-2005, 08:40 PM Thread Starter
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Quote:
Originally Posted by ITPDiesel
on the guinnea pig deal! It's usually us business owners that have the crappy looking test stuff.

I've never talked to DJ, but I was under the impression that he wasn't modifying/replacing the regulator. I thought his mods were to the pump itself.

Hopefully his piece and mine don't look too much alike, I've been working on a replacement regulator fitting as well...wouldn't want to be accused of copying anyone. Big difference is that mine isn't intended to be a standalone mod, it will be part of a complete fuel system setup like we do for the 7.3L trucks. Either way, more power to you and DJ and everyone else that's trying to make the 6.0s scream!

I beleive he is making a kit, banjo, Pressure Excellarator, and lines. I'm not sure though, I know it's being released I beleive next week.

Ring his bell!!!!

305-582-0136
DJ
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post #9 of 37 (permalink) Old 07-30-2005, 09:39 PM
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Quote:
Originally Posted by Choke_On_My_Smoke
Yeah I have the pics of the bolts drilled and how to do it in the "6.0L Banjo Bolt Mod Part I"


thanks though!
I did see that article, I just meant that you didn't specify what size you were drilling the holes to. Don't know if you or DJ have a recommended size for the holes, just thought I would share what I did.

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Race Truck :: 6050# / 11.31 @ 120mph / Best 60' of 1.56 ... with "Built" Race Engine (Fuel Only!)
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post #10 of 37 (permalink) Old 07-30-2005, 09:50 PM
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Quote:
Originally Posted by Choke_On_My_Smoke
I beleive he is making a kit, banjo, Pressure Excellarator, and lines. I'm not sure though, I know it's being released I beleive next week.

Ring his bell!!!!

305-582-0136
DJ
I may have to call him just to introduce myself...sounds like a cool guy!

His kit is quite a bit farther along than mine if it's ready for market. I've been so busy working on the revisions to our 7.3L system for the BTS High Pressure Oil Pump setup that the 6.0L project has taken a back seat. The BTS stuff has been coming together lately and my attention has shifted back to the 6.0L again.

Dennis Schroeder - Co-Owner of Strictly Diesel
Strictly Diesel Webstore / [email protected]
LIKE US on FACEBOOK! / Check Us Out on YOUTUBE!
Race Truck :: 6050# / 11.31 @ 120mph / Best 60' of 1.56 ... with "Built" Race Engine (Fuel Only!)
Race Truck :: 5980# / 10.965 @ 124mph / Best 60' of 1.54 ... with "Built" Race Engine (Nitrous)
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