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| Triple in-engine 6.4L Ford |
This concept of forced induction was conceived as early as the late 19th century by Gottlieb Daimler who patented the technique of using a gear-driven pump to force air into an internal combustion engine. That was in 1885! He had the right idea, and in the 21st century more power is being produced by means of turbo-diesel technology than he could ever have imagined.
Yesterday I came across a 2017 Diesel World article by Jason Sands about a three-turbo 6.4L Ford that cranks out 1,221 hp and a mind-blowing 2,532 lb-ft of torque. Just reading about it makes you want to catch your breath. It had been re-published on the Power Driven Diesel website because they were the team that did the work.
Sands begins by noting how much flexibility there is today with regard to diesel setups. It used to be that you had a choice between a single turbo and a compound two-turbo setup. "Today," he writes, 'there are virtually endless choices, from ball-bearing turbos to large but quick-spooling singles, to compound turbo setups that will support a vast amount of horsepower."
COMPOUND TRIPLE TURBOCHARGERS
Twin turbos have been around awhile, but sled-pullers have been running triple turbos and even quads for years. "It was only a matter of time before pickups followed suit." Here's why triple turbos have an advantage over two. It's not just because there are more of them. First, twin turbos need to make such massive amounts of horsepower that they can be hard to spool, and they make a dent in your wallet. "Instead of a 95 to 106mm turbo, the same amount of airflow can be provided by smaller frame 66 to 69mm turbochargers." In short, sometimes bigger isn't always better. And ultimately, you will have a better driving setup.
The article then zeroes in on the setup for Power Driven Diesel's triple 6.4L setup. The client didn't just want power, he wanted 1200 horsepower, plus he wanted it to be a truck that could tow. PDD's owners --Will Terry and Todd Welch -- said they were up for it.
Got pipes?
The rationale for selecting the BorgWarner turbos that they chose gets detailed, followed by all the decisions as regards how to mount them and run the piping. All of this is illustrated with photos. It was a pretty "wild creation" but they did it in two weeks. Then they tested it on the dyno. They nicknamed their beast "The Hulk." And yes, it delivered the goods.
THE COST
There's no free lunch in this realm. If you want to go big, you can expect to spend something more than a few pennies, but it doesn't have to cost an arm and a leg. Will Terry of PDD says if you want to do a triple setup it will cost between $5,000 and $10,000. This was 2017, and since we haven't shopped around for what's available today, don't take that as Gospel. Nevertheless, it will give you something to compare against.
You can read the full story, along with numerous photos, here:
Triple Threat: Building a Triple Turbo Setup
Why a triple-turbo? Compared to a standard compound-turbo setup the triples use two smaller turbos that spool up quicker to feed the factory high-pressure turbo, which results in them coming on twice as fast. It’s very efficient using expelled heat to drive the turbo. So the number one reason for triple turbos is spoolability. The system is a bit more complicated and costs a bit more, but the results can be worth it.
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