Bought this truck used, and the previous owner has done some mods to it, and I'm just trying to figure out what he's done, and what is normal...

It's a 96 2500 5spd 4x4

First off, there really is no intake "system". There's a ittsy bitsy K&N filter straight on the turbo itself. And I can tell it's not good, because it looks like an accordion. I suppose the turbo sucked so hard that it just twisted and sucked this tiny filter in. I bet it's really limiting my air flow.

There are little zip ties on what I suppose is the wastegate line. I've heard of people plugging wastegate lines with a screw and whatnot, but I've never heard of someone using zip ties. Think those actually work, or should I replace it with some line clamps I have laying around?

This truck really smokes. Before it spools up, I can turn day into night in a 3 lane road if I start in 2rd and get on it a little. Previous owner said his mech "turned" it up a little. I assume the little smoke screw on the back of the afc?

I'm not sure whether or not he's done anything so far as buying/making a fuel plate, how far forward or back the stock/potentially-modified plate is, how far forward or back the afc is, and on and on.

I cruise at 70-75mph at 2k rpm and at about 6 pounds by the gauge at nearly 800 on the pyro. When really rompin on it, max boost I've seen is somewhere around 25. I can smoke like crazy, but I usually drive pretty conservative, but still only net around 16mpg or so, which I would really like to see an increase in...

So anyhoo, sorry if I'm hard to understand, just good off a double after another double the previous day combined with an hour or two of sleep! Brain aint workin too good...

But yeah, throw some ideas at me if yall aint mind too much folks!

 

I would say get an intake system on there 1st then see about your smoke. And check the turbo for wear since it had that oiled k&n on there.

 

I would guess the zip ties are for blocking off the waste gate. I would suggest you get rid of the kn and replace with a bhaf or afe intake. You can also replace the zip ties with a boost elbow for around $25. You can always pull the plate and take a look to see what it is and then you can reasemble and slide afc housing back a little to reduce some if its too much for ya.

 

Turbo's fins still look real good, miraculously enough. Boost elbow worth the price, rather than just blocking off the waste gate with zip ties?

Yeah, plan on turning down the smoke a bit... It's seriously alot for a non "tuned", basically stock truck with no stacks.

With what I've described, does it sound like ~16mpg, or so, is right on par, or should I start looking for other culprits? Cause thats non loaded, and being semi-conservative with the smoke maker petal...

 

First of All we do recommend the boost fitting , It is a more consistent flow and shows better results! I would recommend a AFE stage 1 for the truck!
I would say the Star-wheel is cranked and possible a slid plate! Most Likely to get that heavy of a cloud you'll have to have pretty strong fueling! If the smoke eventually clears your star-wheel is cranked, If it continues to smoke fairly hard after boost your plate is most likely slid or modified! If the truck dose not have gauges watch your foot!
MPG seems close if not a little high from my experience!
L

 

Well, with normal driving once the boost gets up to ~10, then the smoke clears up. Although if I'm really on it, or WOT, it'll smoke till ~20 pounds. I can drive without makin it smoke, but it's REALLY slow going, and I usually get people honking at me. Then I just say "Fine, eat my soot!" lol...

Yeah, I have the 3pod pillar setup with isspro boost and pyro gauges. The top empty pod works absolutely wonderful as a cell phone holder (till I figure out what other gauge I wanna slap in there...)

I think my exhaust system is just dandy for now till I fab me a smoke box and stacks. 3" straight pipe all the way from the downpipe, no cat or muffler, to a 5" tip.

As far as the intake goes, how much would a stock air tube run me? Cause I REALLY couldn't afford a $300 intake system at the moment. Was thinking about trying to find a stock air tube, then go to napa and get me a bhaf. Cause I know that tiny slip on k&n that's sitting straight on the turbo with no air tube is probably about to give up the ghost sometime soon, and more than likely take the turbo with it...

 

The box and Filter Systems as far as stage one AFE's are very affordable,
I have some used boxes, If I can be of assistance give me a call! 828-773-6625 is my Cell!