Blown to bits: Banks boost caps!

[Dieselboy]

I was towing my friend's CJ5 this past weekend, and the EGT was a little on the warm side at 900F with boost topping out at a disappointing 3 pounds. This is on the flat highways of Texas, so something was definitely wrong.

I got to Dallas, and upon inspection, I found this.
http://www.oliverdiesel.com/images/6.2TD/boostfix/blowncaps1small.jpg http://www.oliverdiesel.com/images/6.2TD/boostfix/blowncaps2small.jpg
Sorry for the light, but you can see that the 3/4" ID rubber caps that cover the old CDR fittings on either side of the intake experienced, as my father put it, catastrophic failure.

We couldn't think of anything like the caps that Banks provided, but we did have some of the right sized heater hose laying around. That stuff can handle around 20 pounds, so it was chosen as a temproary fix.
http://www.oliverdiesel.com/images/6.2TD/boostfix/heaterhosefix1small.jpg http://www.oliverdiesel.com/images/6.2TD/boostfix/heaterhosefix2small.jpg

The intake was vented to the atmosphere for the first 200 miles of the trip, so you can imagine my delight with the next 250 miles. The EGTs were steady at 650 on the flat parts, and up to 900 on hills. I finally got to see my wastegate open on the boost gauge at around 10 pounds, so that's going to be turned up to about 12 or 13, and we'll see how that goes.

The next upgrade on the menu will be a new O ring for in between the intake and boost plenum. Thanks for the part number, Peter.

[britannic]

DieselBoy: wow! I'm surprised mine haven't blown as well, since I've had up to 17psi or more working them.

You mention the intake was vented to the atmosphere for 200 miles, how did that happen? I'm assuming the heater pipe was connected in a loop to both of the old CDR inputs?

[Dieselboy]

I guess it wasn't really vented, because gauge pressure would be zero, but it sure was close. :D And I did loop the heater hose around the back of the engine. Also, after looking at the caps, I noticed the seal of quality, Made In China. ;)

[catmandoo]

oldsmobile uses caps like that on the early 80's 350 gassers on cars that didn't return the heater water to the waterpump, instead to the rad.so you had to cap the pipe on the waterpump

[Peter J. Bierman]

I blown off one of the two intercooler pipe sockets once: no boost, EGT at 1100 with moderate throttle, high wisteling sound and NO power at all. I'm supprised you could pull at 900 deg.

Peter

[Eric Deslauriers]

For mine, I turned up two aluminum plugs. Now I just need pieces of heater hose (or in my case, reuse the CDR elbows) and I'm set.

Just a thought.
Eric D
82 Southwind Diesel 6.2 puller

[britannic]

I had occasion to get a look at the caps on mine yesterday and found they're about ready to go like DieselBoy's. They've only been installed a year, but I guess the higher boost levels cause heat stress which leads to premature failure.

[Peter J. Bierman]

I did remove the pipes and put a couple off glow coils in as some sort of extra heat source for cold starting.
You could get the pipes out, tap in a thread and put in a plug.

Just an idea.....

Peter

[britannic]

Originally posted by Peter J. Bierman:
I did remove the pipes and put a couple off glow coils in as some sort of extra heat source for cold starting.
You could get the pipes out, tap in a thread and put in a plug.

Just an idea.....

Peter That's neat! I'm thinking that those two CDR inlet ports may come in useful for adding a water mist injection kit.