Not to open up an older post, but it was only a few months ago. I've recently finished doing a compound setup. I will start by saying before we even get into turbos, fuel, etc.. I will say you NEED oringed heads. I did my gaskets and installed my injectors and an s366. I kept that setup for 4,000 miles. Then I did the compounds and it only lasted another 2,000 miles before the heads had to come back off, and that was on my reduced fuel tune.
At first my setup was fairly simple. Fass 200 with a beans sump, stock fuel system for the rest, other than I had larger lines made to go from the fuel bowl to the heads. I also had a -4 line to connect heads together at the rear. I used 225/100 injectors from Warren. Beyond that, that was it. I got tired of the horrible lagg at 55 with the converter locked.. and wanted compounds. My duramax has compounds and so obviously, the two didn't compare in spool time.
I put the truck down and ordered a windrunner stage 3 intake, a thumper stage 2 hpop, MPD oil cooler relocate kit, BPD water pump, Flex a lite fans, Mishimoto radiator, and of course the turbos. I went for the box 475 as my atmo turbo. It's the same one on my duramax and works great and it is a cheap turbo.. for the high pressure i was torn between a 60mm turbo and upgrade the internals or an sxe362, but went with the 62sxe. After a few weeks of an hour or two here or there it was finished. The only thing I touched for the fuel was I ran the 1/2 inch fass hose clear up to my 3/8 lines and Y'd them. I do not run a return.... though I have 50 psi at WOT at the back of the heads on that -4 line. I really don't see the need for a return since the fass does that already, and it also regulates. One can argue the return gets rid of the air, but my truck runs twice as quiet as a stock truck even with the modified solenoids.
Spool up is like stock. I have not yet gotten new tunes, so it is still running the 366 tuning. The smoke is nearly non existent. No gauges yet so I can only read up to 29 psi. (06-07 truck). I did tow about 6-7,000 lbs with it on that reduced fuel tune, which is slipping my trans and popped the gaskets with studs and brand new gaskets, so it is at least that big of a tune.. and it did great. 1150 was the hottest I saw, and it spools perfect even lugging it. Getting up on the interstate it'll shift into 5th and TC locked at about 55 mph (wasn't using tow haul) and as soon as it dropped into 5th it pegged the gauge and just cruised on up to 75 mph. Cruising 60 mph and rolling into it yields no smoke and immediate spool up. About 1600=1650 rpm to start off. Putting the truck up for winter as it takes several minutes to make oil pressure on cold start because that dumb high pressure pump sucks faster than the poor low pressure pump can move the thick oil. But, if anyone has any questions or concerns I'm open to answering anything and/or trying other things on it! Before winter is over I'll have oil pressure, high pressure oil, fuel psi gauge to monitor 100% of the time, and a 100 psi boost gauge for it. I will put a temporary gauge on the intermediate pipe after all gauges installed just to see what each one does. I have two boost gauges in my dmax, 75/stock setup and the big turbo puts out 22-25 psi for a total boost of 42-45 psi depending on where i punch it. I have a feeling it's going to make over 60 psi though. I also have a triple disc converter to install into it that I acquired for nothing. So far I've gotten no slippage codes, but can see the torque converter is slipping and not holding.
I am done with adding power to this truck, in the future it will get a fully built trans, and I will pull the motor out just to rebuild it. It has 215k on the clock right now. I will be doing oringed heads and 625 studs and a stage 2 cam. Nothing major to the bottom end. I did just slap my heads back on with new gaskets (machine shop had to take off another .006) and hoping that'll get me by until I can fund the mild motor build/trans build. I'm uncertain why the heads needing that much taken off since they were just machined 6,000 miles prior. Motor never saw over 190 ECT or 1150 EGTs during those 6,000 miles.. definitely not enough to warp them. I think the last machine shop didn't do their job properly. The gasket let go in just one small corner by the stud on cylinder 5.
Anyway, I welcome any input!