500 hp what's it take to get there? - Diesel Bombers

5.9L CR Performance Discussion of 5.9 Liter Dodge Cummins Diesels with Common Rail Injection Related To Performance And Longevity

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Old 02-27-2011, 02:52 PM
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Join Date: Feb 2011
Posts: 9
Default 500 hp what's it take to get there?


Hey guys I'm new to this site and have a few questions about upgrading. I have a 2003 Dodge, 3500 4x4 with the HO engine and 6 speed NV5600. MY truck is a daily driver, pull a 30' travel trailer a couple times a year on vacation and I have a low boy trailer I use to pull my Polaris Ranger Crew and hunting stuff with. Oh yeh, light to light race every now and again

The truck has a Dr.Performance 120 hp box and 4" exhaust from turbo back. No other mods.
125,000 miles on the truck and I smoked the clutch the other day.

I would like to get rid of the Dr. Performance box. but get to 500 hp.

What Clutch would you recommend (I was thinking about going with a Valair single disc)?
I wanted to go with a SMARTY and add injectors, what size and make injectors do you recommend (if possible I'd like to increase milage a little). Will the rest of the drive train still be safe? Is all of this an unreasonable fairy tale?

Problem Child
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Old 02-27-2011, 03:58 PM
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Join Date: Sep 2009
Posts: 221

Obviously you'll need the Smarty, but is 500 horses as far as you want to go?

First .... gauges. You're going to need to monitor the boost and EGT's with a 65% increase in power (305 to 500 is a 65% increase over stock).

If it is then 90hp sticks and a lift pump upgrade (FASS or AirDog) would be a starting point, and while you're at it you might as well improve the fuel filtration (add a F/W separator and at least a 5 micron filter). The 90hp sticks should be a good combo of fuel economy and power when used with the Smarty.

Since you're knocking on 500hp, look at a cold air intake and a mandrel bent exhaust. The 4 inch TBE might be okay but if you plan on more than 500hp consider the 5 inch TBE. And while you're under there, go ahead and do the boost bolt mod since the wastegate isn't electrically controlled.

The clutch .... you really need the dual disc, and consider upgrading the input shaft as well since you're increasing your power that much. The single is only rate to around 475hp, and since its a daily driver AND your tow rig, it's not going to do the job you need it to do. Otherwise you'll smoke the new clutch and/or bust the input shaft. I would look at South Bend and Valair's offering in the dual disc 650hp rated clutches.

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Old 02-27-2011, 05:46 PM
reiser's Avatar
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Join Date: Jul 2009
Location: washington, Mo
Posts: 460

well really with a hot tune 500 hp is achievable it'll be a hot 500 as far as egt's go but could be done with just a hot tune....
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Old 02-27-2011, 07:00 PM
Join Date: Mar 2007
Location: Western NC
Posts: 14,547
Default Re: 500 hp what's it take to get there?

Smarty TNT, Thunder 330 Turbo, 90hp Injectors, Airdog, 5" Exhaust, Gauges and Valair Dual Disc Clutch.

Luke B.
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Old 02-27-2011, 08:37 PM
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Join Date: Feb 2011
Posts: 9

Will the stock pump put up enough fuel to handle a SMARTY turned all the way up?

Does anyone make a set of gauges that will match the factory gauges on a 03 Dodge? I have Phantom gauges right now, but at night the entire gauge is back lit, not just the numbers as on the factory gauges.

Which makes the most reliable 90hp injectors?

Sorry for so many questions, but I want to do it right the first tiem and now have to do it again
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Old 02-27-2011, 10:14 PM
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Location: Escondido CA
Posts: 1,713

If you plan on keeping the stock turbo I wouldn't go bigger than 50hp sticks " For Milage"
If not make the check out to lukesdiesel! get it all in one shot! Don't forget to add a lift pump with a 2 micron filter pre CP3! Should be under 6500. for everything!
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Old 03-06-2011, 02:13 PM
coalrollin06's Avatar
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Join Date: Sep 2010
Location: Elko Nevada
Posts: 21

i personally have a airdog 165 5" fbd exhaust afe mega cannon smrty on 9 and quadzilla adrenaline and my valves a few thousands tighter tha stock so they dont float at high rpms.and made 513hp 1368 ftlb on stock turbo and injectors. i know it will be short lived but i got it for now. and you better go with a dual disc.. i smoked a single disc southben but the new dual hasnt slipped once
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Old 03-06-2011, 09:29 PM
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Location: small town MN
Posts: 334

For a tow rig, i know i wouldnt wanna worry about egts. Go with what luke and dangerous said and do it rite and do it once.
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Old 03-10-2011, 11:02 PM
Join Date: May 2010
Posts: 6

I agree with alot of the other posts, however I only heard one person say you should upgrade the charger. I think you can get 500 quite easy with the smarty and a lift pump, (FASS or Air Dog) cold air intake and an Industrial injections fat shaft turbo, there is no need to change out the injectors, I make 700 hp in my 03 CR and I have 90 hp injectors and I wish I had the stock tips back I don't see why you couldnt make 500 without them and put that money into your new southbend clutch. By the way a dual disc clutch is not as drivable as the singles and if you aren't going to race with a load on then I would goto the single.
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Old 03-11-2011, 02:02 PM
Join Date: Mar 2007
Location: Western NC
Posts: 14,547

The New Valair Sprung Hub Nodular Dual Disc is an excellent Daily Driver Clutch. Smoother and better shifting than most singles.
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