Author Archive

Cooling That Powerful Itch

by John Espino
Monday, May 9th, 2005

Some tough questions should be asked when venturing into the world of diesel power: Are you shopping for a product to speed up your truck for quick 0 to 60 sprints and quarter mile bragging rights, or are you looking to enhance its towing brawn? Is there a way to get both? Just why does my truck need to blow plumes of black smoke to make power, and what is it really doing to the engine?

So… what’s the fix? Most folks turn to whatever is the easiest thing they can do to scratch that lustful yearning for road domination: tuners. Tuner manufactures have popped up like crazy in the recent years and due to the advancement of automotive technology these devices can “hack” into the vehicles systems and alter a number of signals to get the desired results. More fuel, more timing, more boost, pulse width modulation, blah blah blah. These work like the man behind the Great Oz by interrupting signals to the various systems, modifying them and making the ECU think that’s its message was received in its original form by saying “pay no attention to the man behind the curtain!” Most of them offer internal systems that monitor the monkey business going on and offer safety nets, but those are the good ones. Some don’t go that far, but reprogram the factory’s OE settings to get the job done. What makes these so tempting is that they can all be installed in a matter of minutes by plugging them in, the majority have multiple power levels and they cost very little to buy. Best part of all is that there’s nothing to maintain.

Sounds great, right? Ah, but there’s a catch to taking that easy road. See, tuner manufacturers advertise numbers you’ll never really reach for long… or at all. Most of them tell you all the benefits you’ll receive under the best of conditions and even feature “Backdown” as a precautionary safety measure, but “Backdown” is actually an amount of fuel and power that the tuner is pulling out when it reaches a given safe EGT. The longer you stay on the throttle the hotter the exhaust gasses get and the more precious power it removes. Hell, some even tell you what percent of the power you’re not getting. Now that’s informative, but wasn’t this purchase about adding power? So what now? Turns out that most of these tuner sales depots recommend a better air filter and a free-flowing exhaust for the cure, but that’s only part of the solution. Getting the vehicle to breathe is a step in the right direction, but it’s not the magic cure. EGTs will go down a bit, but not enough to use that power you were seeking for any real length of time. Why settle for the game of give and take that some tuners play with your truck?

The cure is density my friends! Cool, refreshing density! It’s a rule in the universe (at least this dimension) that a byproduct of power is heat. The more power… the more heat is generated. When was the last time that you got on the treadmill and ran 30 miles without sweating and getting tired? Ok, 30 miles is a little out of reach for most of the human race, but you get the idea. Run whatever you can in an air-conditioned room with plenty of fluids and you can last a whole lot longer. Why is your truck any different?

Why play games when it comes to power? We designed a charge-air cooler that replaces the stock component. The Banks Techni-Cooler System removes the restrictions caused by the common tuner with the ability for greater airflow and density for proper fuel combustion. The result: more power and torque at any EGT… period! Pressure drop and charge air temperatures are reduced while exhaust temperatures are lowered enhancing power anywhere the engine is operating. Mash down the throttle and get the results they promised you while reducing the thermal load on the engine and its cooling system… kinda like that well air-conditioned room stocked with plenty of water I spoke about earlier. Bam! You’re now making smart, lasting power.

Towing? If it’s a boat, a horse trailer or a house on wheels you need that power to eat up the hills. With density added to your system the power remains when you need it most on long, hard pulls and never jumps overboard. What, are you really going to pull over so that the temps can go down just so you can get a glimpse of that muscle you were promised? Not with all those vehicles backing up behind you.

Ok, so I sound like a commercial… I know, but it’s all true. Reap all the benefits of doing the job right and protect your investment at the same time. I’m going to make these points about our system then I’ll bring you back to the program all ready in progress:

* Banks’ boost tubes are larger than stock, streamlined to reduce the number of bends and eliminate the crimped spots
* The CAC design increases density by up to 10%
* Core area is up to 25% larger than stock for greater cooling capacity
* Our bigger end-tanks optimize airflow across the coolers fins for greater cooling
* Melting or bursting caused by extreme boosting conditions is eliminated with the coolers all-aluminum design. No plastic end-tanks to worry about
* Our High-Ram intake ensures the delivery of the oxygen-rich air through its larger and less restrictive shape
* Benefits of the denser air charge and better fuel burn will also result in something everyone’s searching for these days: better fuel economy.

I’m done now. Nah, I have one more thing to say to all the naysayers out there. You know… the ones that want you to believe that we’re just trying to shove more parts on you and shake you down for your lunch money. Ask anyone running a modified turbocharged or supercharged Sport Compact car if more fuel, boost, timing and installing a better intake and exhaust make big power that can be counted on. They’ll look at you with a puzzled expression and ask “what about the intercooler, dude?” These speed freaks are netting power out of a four banger that gas V8s wish they had, and when properly done they live race after race: on the street or on the track. Draw your own conclusions from that.

Shhhh… we’re working on some future stuff!

by John Espino
Wednesday, April 27th, 2005

A little while ago, I wrote in my first blog that we get our hands on some really neat, future stuff. A good example from the past was the powerplant for our Sidewinder Dakota truck. You know… that little red pickup that ended up smashing a number of speed records and went 222 m.p.h.? Well, that engine was a ‘03 common-rail Cummins that we just so happened to get in 2001 from the Cummins Skunkworks for our project.

Being that we are an actual engineering firm, we are trusted (having non-disclosure agreements in place helps) by a number of original equipment manufacturers (O.E.M.s) with some of the newest hardware and technology on the planet. Of course, we keep in close contact with these O.E.M.s through the entire project; letting them know our progress, where we find the good and the bad in their equipment. We share data and make recommendations that sometimes make it to the assembly lines.

Anyway, what I wanted to spill the beans on is the progress of our General Motors Duramax project. Our partners at GM have sent us a number of next-generation engines for our project vehicles, the Type-R (roadrace) and Type-S (street performance truck) that we’ve been hard at work making parts for.

Now, I won’t go into the Sidewinder Type-R Project right now ’cause I’ll write about it in a future blog (behind the scenes highjinks, not just bragging), but I recommend the following link for an over-load of info: (http://www.bankspower.com/projects/show/2-Banks-Sidewinder-GMC-Sierra)

Yes sir, these Duramax projects will get more than just a tuner box that’ll “juice” up their power. Aside from a complement of hard-core racing internals especially designed by us for the Duramax engine, they’ll each get an entirely new “brain.” That’s really what I want to gab about. The brain is based on a design by the Robert Bosch Corporation and the programming is being done from the ground up with the assistance of some equipment from ETAS (a division of BOSCH).

A couple of our engineers were working with a rep from Bosch’s engineering arm in Germany in our diesel engine dyno cell writing programs and tuning the engine. We had the rep here for a week to get us familiar with the software, but by Wednesday they pretty much had everything down and were able to make that engine purr like a kitten, bark like a dog or growl like a lion. Both the Duramax engine and the new brain work in complete harmony.

So, just what did we do with the extra time left that week? I think a better question is what would you do if you had complete control of a powerful diesel engine? Ever heard of the expression “it’s better to ask for forgiveness than permission?”

That’s right…play, and do things you don’t tell the boss about. One thing is for certain, our dogs were taught some new tricks, and the diesel world may never be the same for it.

Turbo Lover: Part One

by John Espino
Wednesday, April 20th, 2005

Have you ever heard a sound that gave you goose bumps just by hearing it? Ever since I was a kid that magic tone for me was that of a turbine whine. To me it just sounds like power incarnate. I mean…what’s more powerful sounding than a jet taxiing and taking off? That is the sound that suckered me into buying my first turbocharged car: the underrated Merkur XR4Ti. I like my vehicles to be different, and this one sure fit the bill. Aside from looking like the forbidden love child of Saab and a Ford Escort, it had a blown Pinto 2.3 liter engine that whined louder than a dentist’s drill. Turbo lag was BIG, but when it finally built up the power its demeanor turned from that of a timid koala bear to a raging donkey and squished my unassuming passengers deep into their seats. Sweeeet! From then on I was bitten by the beast known as the turbo, and its venom went straight to my brain. The true journey to the Dark Side had begun.

The next logical step in my evolution was to become more familiar with my affliction. Sounds simple since the turbo idea itself has been around more than a hundred years, but boy was I wrong! Although in the ’80s and early ’90s all the car companies had some sort of turbo offering, the general knowledge was scarce and tribal talk about them ruled the land. It was as if the turbo was reverse-engineered from the wreckage of an alien craft that crash-landed in a desert somewhere. No one could really tell you anything about them, except that besides making an engine perform like it was a larger one, it was also the cause of any of the evils that happened to a vehicle. Bad mileage: turbo was to blame. Wipers didn’t work: turbo was to blame. Air conditioning wasn’t cool enough: turbo was to blame. Driver had a low sperm count: you guessed it.

Frustrated with my search, I landed a job at a turbo rebuilding outfit called Turbo Master as a teardown monkey. It was a way to get my foot in the door and see the turbo in all its naked glory. To my surprise the turbos ranged in size anywhere from roughly a beer can all the way to that of a teardown bench. There weren’t just ones made by Garrett, but other companies like IHI, Holset, Kamatsu and Mitsubishi to name a few. Aside from the dirty, oily task of taking them all apart…I was in a state of Nirvana.

Beware the Blog!

by John Espino
Thursday, April 14th, 2005

“The Blog!” Blog this and blog that — that’s all I’ve been hearing for the past month. Up until recently I thought folks were talking about the anamorphic amoeba with the voracious appetite that terrorized a small town back in the ’50s flick. They tried to stop it by burning it, shooting it and then blowing it up. Just about the only thing that’d stop it was freezing it. After all was said and done the thing grew from about the size of a pea to a giant glob.

Turns out that blogs actually aren’t going to eat anyone up, just gobble up bandwidth. Blogs have become a way that folks can communicate thoughts and views on things that are important to them, whether it be about business in general or the kind of coffee they like. Our plan is to give a little insight into what’s going on in the industry and what’s going on here at Banks, especially the Engineering and Race Shop departments. Up until now we’ve kept most of this stuff a secret, which doesn’t make too much sense. Some of the projects and products we work on range from technically “cool” to “way out there.” The name of the place is Gale Banks Engineering after all, not “Gale’s Diesel Go-Fast Shack.” We’re an honest to goodness engineering facility first — one that just so happens to be run by gearheads. Think of it as a mixture of NASA meets Q’s workshop from the James Bond films meets Disney Imagineering meets Muppet Labs and you’ll get the picture. As you might guess we’ve got a bunch to talk about, and who knows — you might end up knowing what kind of coffee we like.

So please check back here often. With all the things we’ve got to say, this blog will grow to titanic proportions. Who knows — maybe the only way to stop it will be to freeze it.