So here's the results everyone has been waiting for:
Over a 4 second reduction in 0-60mph times. 4 seconds!!!
So let me go over the entire install/kit/performance and give it a review.
INSTALL
The install is straightforward and anyone can do this. (I'll expand on that in a bit) with nothing more than hand tools and a reciprocating saw. The instructions are completely clear and easy to follow. There a plenty of pictures to help you along as well. The worst part of the install would be increasing the fueling of the injection pump. Only because of the extra care needed to ensure you don't contaminate the pump or break it. While the instructions say that you need to weld all this up. You could get by with clamping a number of the connections with band or c clamps. There are some sections that would need to be welded. But one could get everything installed and take the truck to a muffler shop to have them burn those pipes in. I actually used band clamps on my build to facilitate easier assembly for the crossover pipe install. I did TIG weld up the custom downpipe I made though. Which brings me to the only negative I can say about the exhaust. As a kit, the system is designed to simply drop the exhaust straight down from the turbo. You'd run the exhaust pipe under the frame rail and over to the stock exhaust. I personally didn't want anything hanging below the frame rail, so I passed the downpipe along the passenger manifold. I completely understand why as a kit they wanted you to route it under the frame rail. I had HOURS in making the downpipe. It's actually a 2 piece design as there's no other way to do it. Then I had to reroute fuel, transmission, and electrical connections all through the path I took. For the home install, this would probably be over the top. I ended up using the bandsaw, mill, lathe, hydraulic press, and many other things to make this happen. But for me, it was worth it. So you might also notice how long it took me to get through this install. There were a few issues along the way. There was a defect in one part, but BMI promptly took care of it. Also I've had a few other issues with my install. But more vehicle related than the kit. (Water pump replacement, fan clutch issues, blown transmission cooler liner, dead batteries, snapped injection pump cover bolts, FUN TIMES!) And my main job has taken a lot of my free time lately. If I had followed the kit and not gone rouge on the exhaust, the kit can easily be installed in a weekend.
KIT
The items included in the kit complement themselves well. The manifold BMI has made is of great quality. I'd even go as far to say the casting is more substantial than a factory 6.5 casting for a pickup truck. The oil supply lines and return are all of stainless steel with AN fittings and appears to be a powdercoating. Hoses were Gates as I recall. The airbox is made by BMI as well and is well constructed. The only negative I can find with it is I don't particularly care for the rubber/cork seal used for the airbox lid. I think I'll replace it next time I have it off with a neoprene seal of some sort. Not so much that it doesn't seal. But rather that the rubber tends to want to pick up any trash on it. (I dropped it while working on it and had to pull leaves off the rubber) It's also great they provided boost and EGT gauges. This isn't a knock, but I might end up replacing mine. Not that they don't work. But only to replace with a analog "dial" gauge to fit in more with the stock HMMWV gauges.
PERFORMANCE
Have I mentioned this thing isn't a slouch anymore? The 0-60 alone speaks volumes. My truck is only a 3 speed, so of course top speed isn't really something that can be increased with this kit. But it certainly gets there a LOT faster now. And just cruising around is pleasurable now instead of having it mashed to the floor and not really increasing any speed. If/when I slip in a 4l80e, I will have to probably be able to easily do
interstate speeds. I no longer have to worry about holding up traffic up a hill or in general. As I certainly have plenty of power on tap now for all situations. Also some might be interested in the gauge numbers. From the hilly area I live in, I've only seen 11psi and 980F on the gauges. I did only turn up the pump 1 and 1/8 turn. I might turn it up another 1/8 given the EGTs being low. But I'd like to hook up the DRASH HVAC/GEN trailer and pull it around to see how EGTs work under a heavier load to see if I really have all that much more headroom. Heck, I probably could dial it up a little more as I'm not really going to be pulling trailers with the HMMWV.
Overall
I've had this HMMWV for a number of years. Honestly I kinda had grown tired of it because it was so slow. It just wasn't fun to drive if I have to "think" about every move I make. This kit has changed all that. Power is always on tap and it's FUN again. Now many people simply buy a 6.5TD takeout. But you're going to be at that with the cost of this kit. And the engine swap is going to be way more labor involved than this install. If you have a healthy (Starts easily, runs well, good oil pressure, low blowby) 6.2 or 6.5. I'd recommend just going this path instead of a total swap.
