6.0 Power Stroke turbo faceoff

We put our Ford six liter Excursion on the dyno and proved a simple turbo swap can add 59 horsepower with zero tune changes. Then we stepped up to a bigger charger to see how far stock injector bodies with experimental nozzles can go before fuel becomes the limit.

This truck is a great test bed with a built engine, our ported heads, an intake, and a colt stage two cam. Injector bodies are stock with no intensifier piston mods, just trial nozzles that flow a touch more but are not a final product. Tuning is handled in house using HP Tuners, and we now offer HP tuning for Fords that cleans up smoke with bigger injectors and gives shift on the fly capability. The plan was simple. Baseline the stock turbo, drop in our 62 millimeter, and then our 65 millimeter. The 68 millimeter stayed on the shelf because the fuel system would cap the results on this setup.

The stock turbo cracked 392 horsepower and about 823 foot pounds, but the boost curve told the story. It hit around 27 pounds near 2450 rpm and then slid to the high teens while the engine still wanted air. Swapping to the 62 brought a 59 horsepower gain with no tune change and the power held to roughly 3450 rpm. Peak boost moved to about 30 pounds and it kept around 23.5 out where the stocker was dropping. Next up was the 65 with a small tweak to open the vanes more down low so it would not feel like an exhaust brake off throttle. That setup ran about 470 to 477 horsepower and stayed clean up top with higher boost by roughly two psi through most of the pull. With proper vane control it even matched or bettered the stocker in response. Both chargers felt great on the street and the data showed why. Less drive pressure, stronger boost hold, and a power curve that does not nose over. With stock bodies we skipped the 68 since it would want more fuel to shine.

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