Ultimate Diesel Builder's Guide - - Contents -

Emis­sions-com­pli­ant twin-turbo 6.7L Cum­mins

Na­ture or nur­ture? That's the eter­nal ar­gu­ment over whether or not au­to­mo­tive en­thu­si­asts are born or raised that way. For most of us—in­clud­ing Johnny Ramirez of Payette, Idaho—be­ing an au­to­mo­tive en­thu­si­ast is a learned be­hav­ior. It usu­ally starts with toy cars as a child, and pro­gresses to more ex­pen­sive toys as we get older.

“Grow­ing up, the walls of my room were cov­ered with Dal­las Cow­boys foot­ball play­ers and pages of cool cars and trucks from the mag­a­zines,” Ramirez says. “I grew up help­ing my dad on his truck, and I’ve al­ways loved nice cars and trucks.”

Ramirez’s pas­sion for per­for­mance cars and trucks led into him build­ing some way-cool rides over the years, in­clud­ing a ’70 Mach I Mus­tang and ’07 Shelby Mus­tang, along with some pick­ups. His creative pas­sion for trucks blos­somed into a com­pany, Fu­sion Bumpers, which cre­ates high-end, heavy-duty cus­tom bumpers that are pop­u­lar with diesel en­thu­si­asts. And with that com­pany, Ramirez and his crew have cranked out some way-cool SEMA diesel trucks over the years, in­clud­ing one that landed on the cover of Diesel World mag­a­zine.

The 2013 SEMA project had a bit of a twist to it. Sure, the Ram 3500 had a lift kit, cool tires and wheels, and, of course, a full com­ple­ment of Fu­sion bumpers, but the goal was to build an emis­sions-le­gal com­pound-turbo 6.7L Cum­mins while keep­ing all the emis­sions equip­ment on the truck. Plus, the truck had to be spe­cial since it was the first year Fu­sion had a booth at the an­nual SEMA show and wanted to make a good first im­pres­sion.

“With help from our friends in the in­dus­try, we built a very unique truck,” Ramirez says. “It fea­tures many new prod­ucts and was the only 2013 Ram with a com­pound-turbo setup us­ing twin CP3S and re­tain­ing all the emis­sions equip­ment. Plus, it was the per­fect project to dis­play our new stain­less steel Fu­sion bumpers.”

Ramirez started out with a fresh 2013 Ram 3500 Mega Cab that was given the longbed stretch treat­ment by Pre­ci­sion Body Line of Salt Lake City, Utah. The long bed for the stretch was supplied by Long Bed Con­ver­sions (Longbed­ BDS Sus­pen­sion re­port­edly used the truck to pro­to­type an 8-inch, long-arm sus­pen­sion sys­tem for the 2013 Rams, com­plete with dual Fox 2.0 re­mote-reser­voir shocks and 8-inch Pro-ride coils up front. At the rear are BDS Glide-ride leaf springs with an­other set of Fox 2.0 shocks. Cov­er­ing the 3.42 gears in the rear diff is a Street to Sand cover. The lift pro­vides plenty of room for 38-inch 15.50x20 Toyo M/TS mounted on wide 20x12 BMF forged and pol­ished AWOL wheels.

While you wouldn’t know it at first glance, since all the fac­tory plas­tic cov­er­ing the 6.7L Cum­mins is still in place, the real magic is found in the ATS Aurora 7500 com­pound-turbo kit mounted to the left. Ac­cord­ing to ATS, the com­pany had been work­ing on de­vel­op­ing an emis­sions-le­gal setup and Ramirez’s 2013 Ram was the first truck to get the Aurora 7500 com­pound-turbo kit. Sup­port­ing the sys­tem is an ATS Dual Fueler setup, an­other first for a 2013 truck ac­cord­ing to Ramirez.

Ac­cord­ing to ATS, the Aurora Plus 7500 com­pound-turbo kit and Dual Fueler combo are de­signed to work with all the fac­tory emis­sions sys­tem com­po­nents, in­clud­ing the DPF, and keeps all the emis­sions sys­tems op­er­at­ing as

de­signed. The Aurora Plus 7500 sys­tem also uti­lizes its own air in­take. The sys­tem was in­stalled on Ramirez’s Ram so it could un­dergo real-world CARB cer­ti­fi­ca­tion test­ing and eval­u­a­tion.

For in­surance, since the tur­bos can make upwards of 60 pounds of boost, a set of ATS head studs was in­stalled. Feed­ing the Dual Fuel­ers with clean #2 is a FASS 150-gph sys­tem. Cus­tom tun­ing was pro­vided by H&S Per­for­mance for al­laround per­for­mance and tow­ing ca­pa­bil­ity. The combo makes more than 650 horse­power and 1,200 lb-ft of torque.

To han­dle the ad­di­tional torque and horse­power, the orig­i­nal Aisin trans­mis­sion was re­placed with an ATS Stage 4 trans, com­plete with an ATS 5-Star con­verter and ATS Tow­ing Edi­tion valve body. Other mods in­clude a bil­let flex plate and bil­let in­put shaft.

In or­der to make an­other first-class SEMA truck with all the right stuff, Johnny en­listed the aid of his friends at Street to Sand Off-road in Reno, Nevada, for all the body mods. First up, match paint­ing the fac­tory mir­rors and door han­dles, and smok­ing the head­lights. Fu­sion Bum- pers’ new stain­less steel bumpers were added front and rear, and were fit­ted with Rigid In­dus­tries’ Q-series LED lights up front and 4-inch E-series LED lights out back. A Sta­tus grille sets off the front end nicely.

The bed is cov­ered by a Re­trax-pro ton­neau cover, which hides a Cargo Glide CG 2000XL pull­out that’s mounted over a Bed Rug. Amp Re­search Pow­er­steps and a Bed Step help with en­try, exit and bed ac­cess. A set of match-painted EGR fender flares helps cover the 38-inch rub­ber. The fin­ish­ing touches were cus­tom graph­ics

by Trans­guard in Boise, Idaho, and a set of train horns mounted un­der the truck, which are fed by a Vi­air air tank and com­pres­sor sys­tem.

On the in­side, the truck is just as cus­tom as the out­side, fea­tur­ing match-painted trim pieces, pan­els and door trim from Elite Cus­toms in Reno. A bil­let switch panel is mounted in the cen­ter con­sole while Husky Lin­ers front and rear pro­tect the floor. For at­mos­phere, the stock head unit was re­tained so it can func­tion with the orig­i­nal steer­ing wheel con­trols thanks to a JL Au­dio Clean Sweep in­ter­face. Pow­er­ing the sys­tem is a pair of JL Au­dio HD 1000 amps. In terms of play­back, all the stock speak­ers were re­placed with JL Au­dio 2 Series speak­ers. A pair of 10-inch 10W3 subs are mounted in a cus­tom en­clo­sure on the back wall of the Mega Cab while two more are fit­ted un­der the rear seat to round out the mu­si­cal ca­pa­bil­i­ties of the cus­tom Mega Cab.

Need­less to say, the truck is es­sen­tially a one-off cus­tom, which is ex­actly what a true en­thu­si­ast would want it to be. For Johnny Ramirez and crew, mis­sion ac­com­plished. UDBG

Out back are BDS Glide-ride leaf springs with an­other set of Fox 2.0 shocks damp­ing mo­tion. Cov­er­ing the 3.42 gears in the rear diff is a Street to Sand rear diff cover.

Twin Fox steer­ing sta­bi­liz­ers help keep the Ram pointed straight down the road.

Rolling stock on the Mega Cab con­sists of 38-inch 15.50x20 Toyo M/TS mounted on wide 20x12 BMF Wheels forged and pol­ished AWOL al­loys.

With all the fac­tory plas­tic and emis­sions equip­ment still in place, you would think this is a stock 6.7L Cum­mins as op­posed to a com­pound turbo mon­ster that cranks out more than 600 horse­power and 1,200 lb-ft of torque.

The se­cret to the big power is an ATS Aurora Plus 7500 com­pound-turbo setup mounted on the truck. Part of the sys­tem is ATS Dual Fuel­ers. The sys­tem is de­signed to work with the fac­tory emis­sions equip­ment to keep things street le­gal.

The in­te­rior fea­tures match-painted trim pieces, pan­els and door trim from Elite Cus­toms in Reno, Nevada. A cus­tom bil­let switch panel is mounted in the cen­ter con­sole. A whole host of JL Au­dio com­po­nents, in­clud­ing speak­ers and amps, pro­vides the...

A FASS 150 fuel sys­tem pushes clean diesel fuel for­ward to the Dual Fuel­ers.

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