2003 Ford F-250: Project Outcast Part 7 Photo Gallery
More Fuel For The Fire
Mike McGlothlin –
Jul 1, 2013
Photo 1/14 | 2003 Ford F 250 Project Outcast Part 7 On Dyno | 2003 ford f 250 project outcast part 7 on dyno
Photo 2/14 | 2003 Ford F 250 Project Outcast Part 7 Fass Fuel System And Injectors | 2003 ford f 250 project outcast part 7 fass fuel system and injectors
Photo 3/14 | 2003 Ford F 250 Project Outcast Part 7 Elite Diesel Fuel Injector | At the heart of this month’s horsepower recipe sits a set of Elite Diesel Engineering’s Stage 2 Tow Power injectors. They flow a maximum volume of 185 cc and are fitted with 70-percent-larger-than-stock, extrude-honed, 8-hole nozzles (factory nozzles are 6-hole). While these 185/70 injectors retail for $3,250, Elite also offers a Stage 2 DIY injector kit for budget-minded enthusiasts, which allows you to build your own set for just $950.
Photo 4/14 | 2003 Ford F 250 Project Outcast Part 7 Fass Titanium Series Fuel System | Our 125-gph FASS Titanium Series fuel system (model T-F14-125G) came from Strictly Diesel. It’s important to note that a healthy stock fuel pump on the 6.0L Power Stroke can support up to 190cc injectors, so it wasn’t absolutely necessary to bolt on the FASS system this month. However, since we plan to bump up to Elite’s 205cc injectors, and then its 225cc injectors in the future, installing the system now rules out adding this mandatory mod later on. Plus, by adding the FASS system now, we know the injectors will be fed plenty of fuel, and that we’re not leaving any horsepower on the table.
Photo 5/14 | 2003 Ford F 250 Project Outcast Part 7 Fass Fuel And Air System Installed | The Titanium Series fuel and air separation system uses the same proven features found in FASS’ HD Series for Class 8 applications (including the fuel pump), but in a more compact overall package. The system’s smaller size allows you to mount the pump closer to the truck’s frame, keeping it both safe and less visible than larger systems. Following FASS’ directions, we mounted the system just in front of the driver-side rear leaf spring pack.
Photo 6/14 | 2003 Ford F 250 Project Outcast Part 7 75 Psi Regulator Spring | Prior to sending us the FASS system, Dennis Schroeder of Strictly Diesel installed this custom, 75-psi regulator spring in the fuel pump. The added pressure is required in 6.0L and 7.3L high-pressure fuel supply systems and allows the engine-mounted fuel pressure regulator (included in the regulated return kit) to manage the engine’s overall fuel pressure. Without this spring, fuel supply pressure making it to the regulator would be too low.
Photo 7/14 | 2003 Ford F 250 Project Outcast Part 7 Strictly Diesel Regulated Return Kit | Strictly Diesel’s regulated return kit offers adjustable fuel pressure capability for ’03 to ’07 6.0L Power Stroke engines and stops fuel from dead-heading in the fuel rails within the cylinder heads. With consistent and increased fuel flow through the heads, each injector receives adequate fuel and more power can be made. This is accomplished by connecting both fuel rails together via a bypass fuel pressure regulator that is located after the fuel demand and pressure drop occurs (not before it). Kits come with everything you need to scrap the old fuel system entirely, including custom CNC-bent stainless steel hard fuel lines, stainless steel braided Teflon fuel lines with a black protective covering, high-flow banjo bolts, and detailed install instructions.
Photo 8/14 | 2003 Ford F 250 Project Outcast Part 7 Driven Diesel Bypass Regulator | A high-quality bypass fuel pressure regulator supplied in Strictly’s regulated return kit comes from Fuelab. It allows you to precisely control how much fuel pressure is making it to the injectors. We installed our regulator on the supplied stainless steel mounting bracket and set the fuel pressure to 65 psi (65 to 70 psi is recommended).
Photo 9/14 | 2003 Ford F 250 Project Outcast Part 7 Driven Diesel Fuel Return Fitting | This custom-machined return fitting assembly bolts to the side of the fuel filter housing, thereby taking the place of the blue spring, poppet (which gets removed), and factory cover. It effectively caps off the factory regulator, allowing fuel pressure to be regulated after the fuel rails, as opposed to before them.
Photo 10/14 | 2003 Ford F 250 Project Outcast Part 7 Fuel Pressure Gauge | Here you can see the fuel pressure gauge mounted on the regulator. The fact that Strictly Diesel provides a Marshall liquid-filled fuel pressure gauge with its regulated return kits is a nice touch. In our experience, non-liquid-filled gauges typically don’t last very long on diesel engines (the constant vibrations tend to kill them).
Photo 11/14 | 2003 Ford F 250 Project Outcast Part 7 Cfm Plus Intake And Intercooler Tubing | Doing away with the restrictive factory intake elbow is one from CFM Plus. Opting for the company’s complete LargeMouth kit, we also installed a larger, 3 1/2-inch steel intercooler pipe. For precise fitment, the bent steel intercooler tube is reduced at the end that connects to the intercooler.
Photo 12/14 | 2003 Ford F 250 Project Outcast Part 7 Ford 6 0l Power Stroke | Things are starting to look a little more modified under the hood of our ’03 F-250. According to our chassis dyno numbers this month, we estimate the 6.0L Power Stroke is pumping out somewhere in the neighborhood of 570 hp at the crank.
Photo 13/14 | 2003 Ford F 250 Project Outcast Part 7 On Dyno | Back on the dyno (and under load) at Randall’s Performance, we saw 33 psi of boost and EGT peak at 1,500 degrees. For the majority of each dyno run, EGT stayed below 1,350 degrees, so a quick spike to 1,500 didn’t worry us. ICP voltage held strong at 4.7 volts (meaning more than 3,500 psi of injection control pressure), fuel supply pressure never budged off of 65 psi, and an ideal injector pulse width of 2.5 milliseconds was observed.
Photo 14/14 | 2003 Ford F 250 Project Outcast Part 7 Dyno Graph | 2003 ford f 250 project outcast part 7 dyno graph