Tuesday, July 3, 2018

We Love the 6.7L Cummins!

The Cummins crowd is a unique bunch.  There's so much history around the brand; over the last two decades, the 5.9L and 6.7L Cummins variants found in Dodge/Ram trucks essentially created a big part of the diesel performance universe.  Some folks like to say the Cummins engines sound like they're straight out of a tractor, but we know better - these engines came from a company that is known for making diehard diesel equipment.  You can hear echoes of the 'big brother' engines when you listen to a Cummins-powered truck.  You could almost say Cummins is a religion to some.

We've always admired Dodge/Ram trucks.  We've got employees driving them into work, some of our staff had them growing up, and at least one drove a couple of Cummins-powered trucks around a 40,000 acre cattle ranch for several years.  Beyond that, we've seen them do amazing things in contests like the Diesel Power Challenge.

We were interested to hear if Cummins owners were having any EGR cooler issues, and it turned out that yes, some are.  The causes and symptoms are a bit different than Power Stroke EGR coolers.  It seems clogging can be an issue with 6.7L Cummins EGR coolers, and there's a factory recommendation that they are removed and cleaned out every 67,500 miles.

We're gonna go out on a limb here and say no one really wants to remove their EGR cooler every 67,500 miles.

We've now designed and tested BulletProof EGR coolers for the 6.7L that feature our H-CORE technology.  If you're not familiar with H-CORE, check out this short animation - it really provides a quick, easy-to-understand explanation of why it's better than other designs.

Our EGR coolers tend to do well where others will clog up, so we aren't going to recommend any kind of cleaning procedure.  That's one less thing to worry about for truck owners.

We're excited to start supporting the Cummins community.  Everyone knows we offer high-quality upgrades for Power Stokes...now it's time to offer the same to our bighorned pals.

Check out our Cummins offerings here.

Monday, June 25, 2018

Fleet Maintenance Magazine Article

Check it out - an article we wrote for Fleet Maintenance Magazine has been posted online.  Bullet Proof Diesel has provided an 'upgrade' option that previously didn't exist for fleet managers, who often had to deal with problematic EGR coolers.  Click here to read the article.

Wednesday, June 13, 2018

The 6.0L and 6.4L Power Stroke Engines - Some Key Differences

The 6.0L Power Stroke
After a successful run with the 7.3L Power Stroke (which was discontinued due to rising emission standards rather than performance issues), Ford again sourced International to build their diesel powerplant for pickups and vans.  The 6.0L Power Stroke, first released in 2003 model-year vehicles, was notable in that it featured a variable geometry turbocharger, the first Ford had offered.

Most of us know what happened: inherent problems with the 6.0L (we call them 'pattern failures') caused the engine to become notorious for constant headaches.  In 2007, Ford released the 6.4L Power Stoke, with hopes that the headaches would fade, but all-too-common problems often crippled the engine's reputation.  Bullet Proof Diesel was the first to offer fixes for these pattern failures, and today reliability can be achieved in either engine.

Here are a several key differences between the 6.0L and the 6.4L:

  • The coolant paths are different.  Often, a failed EGR cooler in the 6.0L stemmed from a clogged-up oil cooler, which wouldn't let coolant flow into the EGR cooler.  The 6.4L has separate coolant passages for the oil cooler and the EGR cooler.
The 6.4L Power Stroke
  • The oil coolers are different...kinda.  We mentioned plugged-up oil coolers in the 6.0L above; Ford responded to this problem by adding an extra coolant layer in the stacked-plate oil cooler.  It was an imperfect fix, as oil coolers in 6.4L's still regularly become clogged with coolant debris.
  • The 6.4L has two EGR coolers.  One horizontal, one vertical.  A lack of coolant can cause either one to rupture.  The 6.0L has one EGR cooler.
  • The 6.4L has two turbochargers (one 'low' pressure and one 'high' pressure).  When the engine was released, it was the first light truck diesel to feature more than one turbo.
  • The 6.4L uses a Diesel Particulate Filter (DPF).  The 6.0L pre-dates Ford's use of DPF.

Other differences are more obvious; the larger displacement of the 6.4L helps it to create a bit more power than the 6.0L ever did.  The 6.4L is rated at 350 horsepower and 650 ft/lbs of torque compared to the 325hp/570ft/lbs made by the 6.0L.

The 6.0L was produced for five model-years, 2003 to 2007.  The 6.4L was produced for just three, from 2008 to 2010.  As such, 6.0L parts and components seem to be a bit more readily available and at better prices.  Perhaps the smaller number of 6.4L-powered trucks on the road is the cause of this disparity.

As a parting shot, we should mention that there are Bullet Proof Diesel solutions for both engines.  In fact, lots of our employees drive a 6.0L or  6.4L trucks.  As stated above, reliability can be achieved in either one
The BulletProof 6.4L 2 EGR Complete Kit


Wednesday, May 23, 2018

H-CORE Technology Available for the First Time in 6.0L EGR Coolers!

If you haven't seen the video showing how our exclusive, patented H-CORE technology works, you might be surprised at how simple the concept is.  We all know stock EGR coolers have been problematic in a number of different engine platforms.  When we started looking at commercial applications, it became apparent that the OE design had to be completely abandoned to achieve reliability.

You may have seen our upgraded straight-tube replacement EGR coolers in 6.0L EGR coolers.  When we tested this design in larger EGR coolers (found within medium duty commercial trucks), it became apparent that heat expansion was going to be a problem.  Straight tubes at a certain length simply expand too much and cause internal rupture situations.

Our persistent leader here at Bullet Proof Diesel, Ken Neal, went back to the drawing board and a 'Eureka!' moment eventually came - rather than keeping the tubes straight, perhaps they could be braided, so much of the tube expansion could be directed laterally.  Well, to make a long story short, a machine had to be invented to braid the tubes, a lot of patent paperwork followed, but the idea worked well.  In lab tests, the force at the end of the tubes was 4x less when they were 'twisted'

We first used H-CORE EGR cooler internals for medium-duty trucks, but recently we decided to use the technology in the product that put us on the map: the square 2004-2007 6.0L EGR cooler.  It's just another improvement in our never-ending quest for ultimate reliability and dependability.  Check 'em out online by clicking on this sentence.

If you have one of our straight-tube BulletProof EGR coolers, don't worry.  We have and always will maintain a limited lifetime warranty on the part.  But in all probability, you'll never need to utilize the warranty, as the failure rate is far, far less than 1%.

Thursday, May 17, 2018

Chase Truck Update!

Here's an update on the flagship chase truck we're building for our Baja support fleet-

Suspension, wheels, tires, lighting, bumpers, bed, radio, P/A...it's all installed!  Next our team got busy fabricating the rack and other custom features.  We recently got the rack back from powdercoat, secured it to the vehicle, and then installed the transfer tanks.  This thing is starting to look pretty serious - and wait until we show you the super-trick kickout steps!

More to come...

Tuesday, May 8, 2018

We've Got Third Brake Light Antenna Mounts For All the Big Three!

Ram, Silverado, and Sierra Owners Can Join the Fun!
We've long produced the Third Brake Light Antenna Mount for Ford pickups.  After all, we started making them for aluminum-bodied trucks.  Obviously magnets won't work on aluminum, and most folks just don't like the idea of drilling into their truck body for an antenna mount.  

Our Ford offerings fit the following trucks: 
We were happy to hear that our customers liked the mounts, but we were surprised when they requested them for other trucks.  Steel-bodied trucks.  Trucks that can use magnetic mounts.  Well...magnetic mounts can mar the paint of a truck as it wobbles in the wind.  Additionally, it looks temporary - the antenna cable is usually routed in through a window when a magnetic mount is used.  People who regularly use radio communication, it turns out, don't really love those magnetic mounts.

Well, we're here to help!  We've expanded the Third Brake Light Antenna Mount line to include:
One of the best features of this product is the ease of installation.  Unscrew the brake light housing, unclip the power wire, put a couple of bolts in, reconnect the power wire, then screw in the antenna mount and brake light housing.   A few short minutes, and you'll be ready to roll.

Should we further expand our line and 
offer more applications for the Third Brake Light Antenna Mount?  Let us know!  Email us at customerservice@bulletproofdiesel.com

Thursday, May 3, 2018

It Begins! Our 2018 F-350 Becomes the Flagship of the Bullet Proof Diesel Chase Fleet.

It was time for a new chase truck...

Ken Neal and the Bullet Proof Diesel race support team have been running the pits for Cameron Steele and the Desert Assassins for many years.  In fact, being down in Baja and learning which support truck parts needed upgrading helped serve as direct inspiration for many Bullet Proof Diesel products.

Ken's 2004 6.0L-powered chase truck has run many a Baja dirt road, and we also have Kenny Kreuter's 6.4L Super Duty in the support fleet.  If needed, we've also got a F-350 dually and a 6.0L Excursion that can be utilized.  That said, it was time to look forward, to check out the new technology found in trucks, and to see how the 6.7L Power Stroke does in a chase truck.

Pow!  This past February, Ken showed up at Bullet Proof Diesel headquarters with a 2018 Cab & Chassis F350.  With a wicked smile, he said "Let's build this thing!" and the project began.

We've got a dream team of companies supplying product: BF Goodrich, BDS Suspension, Fox Shox, Method Race Wheels, Rigid Industries, Addictive Desert Designs, 

We'll be showing the steps to the build on social media, and Diesel World Magazine is going to cover the process as well!  This truck will be a top-level support vehicle, chasing trophy trucks - it's just not something you see built every day.  So join the fun, follow us on Facebook and Instagram, and watch as our new flagship is assembled!