5.9 kegger mod almost done ( tig welded) - Page 3 - DodgeTalk : Dodge Car Forums, Dodge Truck Forums and Ram Forums
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post #41 of 47 Old 10-04-2009, 09:17 PM
spun360
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tell me what you think. i may use soft weld, or alu brazing rod some people call it. it welds at something like 2000*,map gas torch. w/ this i will affix a plate in the mani. after i trace and cut an alu sheet to replace the steel plenum pan, i will make one large turtle back out of the left over 1/4". i may need to preheat the mani to boost up the mas to temp in order to braze in a plate, via BBQ. wish i had access to a tig weld. was it luck or skill, i herd its tough not to damage cast alu! good job.
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post #42 of 47 Old 10-04-2009, 09:39 PM Thread Starter
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It was not bad as I thought! I actually think being a cast piece is better than say a form pressed or plate intake. The cast took the heat very well. As far as the aluminum rod you use a map torch on, I don't think you can generate enough heat in the weld area on the intake, the plate your using will heat up faster than the cast? But I have never tried it, I would make damn sure to prep the areas on the intake were your welding with some type of grinder or carbide bit to get thru the cast finish of the intake. That way you get thru that outer layer of aluminum. I'm not saying an 1/8" but knock it down till it is shiny clean and smooth, so that stuff will adhere good!

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2000,2500 ext-cab 5.9 4/4
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Brass cap and rotor
Hughes plenum pan
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post #43 of 47 Old 10-20-2009, 08:14 PM Thread Starter
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Sorry been so long for the update, but been dealing with some identity theft issues! The intake works great! Disconnected the battery, and let the PCM learn from scratch. Seems to pull much better and longer up top. Strange thing is my mileage seems a little better haven't topped it off yet to check, but it seems like it takes just a little less to get to work than before. I will check on the mileage soon, I was at just under 16mpg, if it improved at all that would be a Bonus! LOL (PS at least when my foot isn't in it! )

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2000,2500 ext-cab 5.9 4/4
5-speed 4:10's
Brass cap and rotor
Hughes plenum pan
Modified TPS
Center Force II clutch
JBA 8mm wires (w/ horizontal wire looms)
New Viton valve seals
stainless steel shorties
180* T-Stat
AIS Ram Air Box (dual snorkel)
Ram side exhaust 3" in 2 1/2 outs magna flow
next harland sharp rockers, and TB
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post #44 of 47 Old 10-20-2009, 08:47 PM
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I have been pondering the benefits of filling a kegger for my own driving and I think that my mileage should improve as well. Filling the plenum is supposed to move the power band down, if you have more power at a lower rpm it means that you need less rpm to maintain a given speed. I try to cruise at 1500rpm-1500rpm, but this puts me at just at about 35mph-45mph, and most of my driving is is in 40/45 mph zones, so I am hoping that when I fill my plenum I will be able to maintain my 1500 rpm goal and be able to keep up with traffic.

Does this sound logical?
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post #45 of 47 Old 10-21-2009, 04:41 PM
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in other words the rpm at normal 50m/h are near 2000. the oem kegger doesnt breath, the flow rates break up at 1500. to mod looses low end torque, moves the power band higher, and creates better flow rates. this is caused buy clearing a straight shot for air," shortening runners", filling the dormant cavity, "epoxy, alu, what have you". it gets rid of the birp of air at low end and lets you resperate at mid rpm. does that help?
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post #46 of 47 Old 10-21-2009, 07:06 PM
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What if you just fill the top of the kegger without cutting the runners?

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post #47 of 47 Old 10-21-2009, 10:21 PM
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Quote:
Originally Posted by Harrison_Berger View Post
I have been pondering the benefits of filling a kegger for my own driving and I think that my mileage should improve as well. Filling the plenum is supposed to move the power band down, if you have more power at a lower rpm it means that you need less rpm to maintain a given speed. I try to cruise at 1500rpm-1500rpm, but this puts me at just at about 35mph-45mph, and most of my driving is is in 40/45 mph zones, so I am hoping that when I fill my plenum I will be able to maintain my 1500 rpm goal and be able to keep up with traffic.

Does this sound logical?
\

No it's wrong. The RPM of the engine in a certain gear will be the same at the same speed. If you're in OD at 45 doing 1500 RPM with a stock kegger, you'll be doing 1500 RPM at 45 with a modded kegger. Axle and driveline rotation will not be affected by the intake, just throttle response.

Where the change comes in is throttle position. If you're at, say 30 percent throttle to maintain 45 MPH and 1500 RPM with the stock kegger intake, but you mod it and now you're at 25 percent throttle to maintain the same speed and RPM, you're using a tad less fuel. (mind you these numbers are probably not accurate in correlation with eachother just using as reference)


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2000 Dodge Ram 1500 Single Cab, 5.9 Auto, 4.10's, Auburn LSD, Edelbrock headers, 2.5" true duals with crossover, MSD Superconductors, APS Plenum Kit, Level10 Trans kit, Trans-Go shift kit, 2-4 BellTech Drop, SS/T rims, Toyo Proxes ST 285-60-17's, Sir Michaels Roll Pan and tailgate handle relocator, Keystone bumper cover with light openings, PIAA fogs, painted grille shell, painted Street Scene Speed Grille Inserts, SCT XCAL-2, Alpine head unit, Infinity Components front, Infinity Coaxials back, Infinity 500W 4 channel amp, Infinity Basslink, new dash, steering wheel, and guage bezel.

1996 Dodge Ram 1500 Club Cab, 5.9 Auto, 4.10's, Detroit Locker, Race Truck Trends Nascar Bumper, Painted SS/T Stripes, Alpine HU, Alpine Sound Field Processor, MTX Thunderform. 5.9L bored .030 over, Sealed Power coated pistons, balanced and polished crank, Comp 210 Cam, MP Timing Chain tensioner, Melling HV oil pump, 1.92 oversized valves and mild porting, Pacesetter Longtube Headers, FMS 24lb Injectors, Level10 Transmission kit, Trans-Go shift kit, 5 gear OD Planetary. Way more to come.
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