Sadly, We could not overcome the leaking intercooler and could not break my goal of 700 HP.
Adding more boost just clamped down on the exhaust while pissing the extra air out of the leak. Net gain, nothing. I had plenty of fuel, just needed some more air to mix with it. Without the leak, I probably could have gotten another 30 HP. At the end of the day, I think the leak had gotten worse since the numbers were starting to fall off.
Ended the session with 691/1205 as the best run. Max torque around 2700 RPM and Max HP in the 3300 range. We only pulled to 3900 RPM, but the HP curve is near flat to the lift point losing only about 50 HP from 3300 to 3900.
Found the edge of what the 6 yr old Suncoast III in the tranny will hold. It started rejecting full throttle in 5th gear during the road testing.
The max effort tune is fun. On the way home, someone tried to box me in behind a line of big rigs with one of those SS pickups. Blipped the pedal and scared him and me as I went from 70 to 90+ in a little over two car lengths. Scared him because he had just rolled on his throttle to close the box and he wasn't expecting a diesel to jump out like that. Scared me because a great burst of power like that is usually followed by a loud bang as something breaks.
Max tune is rough around the edges IMO and suffers from surging down low. I will massage it after I fix the damn leak.
Had a big, big scare when I fell victim to the LLY injector harness failure. Sounded like a piston was about to come out of the side of the engine when the #7 injector cut out. Reset the code a couple times hoping to find a good spot to work on it once I figured out it was the harness. BUT couldn't make it to the next exit. So I used a utility knife and did the dirty deed on the side of I-70 just inside the western edge of Ohio.
