If you listen to Gale Banks' discovery of air density's effect on power and all the race records he's set over the last several decades, you'd discover that one of the main reasons for power loss is due to low air density. He raised the bar at Pike's Peak and with all the mods done to the race truck at Pike's Peak (Super Turbo, 2500hp, 4000tq with a 14L Int'l diesel, instant acceleration, and no black smoke), he was able to achieve constant power through all the elevation changes with no density loss at over 14k ft elevation. The reasons for power (& heat) loss include poor air density, intake air temperature, altitude, ambient air density, and boost air density. More air density going into the engine means more power, regardless of how much boost you have. The hotter the air, the less dense it is, and less power results. Diesels get hotter when fuel is increased without an increase in air density. Hotter EGT's also means more heat is transferred to the oil and coolant, which then has to be expelled. If you increase boost air density (cooler air is denser air), the intake air temperature becomes more optimum, more fuel economy and power results, and more fuel is converted into energy. So if you removed 100% of that heat (but you probably won't be able to), your crank HP would be 936 HP, and wheel HP would be 786. 100% fuel efficiency at 690 CHP & 550 WHP(which would be almost impossible to achieve) I calculated to be 2,362 CHP & 2,222 WHP. So the more you can bump up air density, the more power and fuel economy you'll achieve. The denser the air, the more efficient the engine becomes while making power; less black smoke results, and less heat gets transferred to the oil and coolant. Also, I'd look into Banks Power intercooler and radiator. I don't currently see them listed for the 12 valve, but you might be able to call them and special order those 2 items for maximum cooling and air density.Mishimoto used to make a 2-row radiator but I believe they use a 3-row design now. I wonder what the capacity of the 3-row is compared to the alternatives? I bought an eBay 4-row unit designed for a 2nd gen Ram at one point but it interfered with my BD intercooler. I don't know if it would have interfered with the stock intercooler.
Did a quick search and found this interesting paper: https://theicct.org/sites/default/files/publications/HDV_engine-efficiency-eval_WVU-rpt_oct2014.pdf
They look at two diesel engines, and the smaller is a 6.7 "medium-duty" unit. According to their study, 29.2% of its fuel energy was converted to usable horsepower and 10% was rejected to the cooling circuit. I don't know which engine they were looking at specifically (I might be inclined to guess) and I'm betting that it is more efficient than our old 12V engines, but it's interesting information regardless. Let's say it's representative. That would mean that for our truck the crankshaft HP is 29.2/10 of the power rejected to the cooling circuit. Now assume 550hp wheel hp is approx 690 (=550/0.8) crank hp. That would mean heat rejected to the cooling circuit & radiator is 236hp (=690*10/29.2) which is 176kW which is 600500 BTU/hr. That's a LOT of heat. I like the idea of adding a secondary heat rejection circuit for the oil system but even a stout secondary cooler will probably only reject a relatively small fraction of the 60500 BTU/hr total heat rejection. I used one of the really nice Derale coolers for my transmission and my recollection is that it rejects something like 25hp peak (and that was spotty information, didn't list inlet temperature, airflow, ambient temperature, etc).
Oh wow, you even have the AFC Live from PDD installed!Kilamat done. Single layer all pressed down. Already did door panels years ago. Closed cell foam layer is next then new carpet, speakers, headliner and seats are being redone at shop including new foam from Geno's and seat heaters. Dash cap being fitted at this time also. Black for carpet, headliner and visors. Seats will be red and black vinyl pattern.
72sq ft kilamat was used. I just put it down the best I could.... Not for show anyway.