1,000 Horsepower 2007 LBZ Duramax Street Truck

Collin Casstevens Aims For 1,000 Horsepower With His 2007 Duramax Street Truck

How many of us have bought a truck thinking, “I’ll just do exhaust and a chip?” How many of us have actually stopped there? Collin Casstevens from Middletown, Indiana, had the same idea when he bought his 2007 GMC Sierra 2500—until he caught the diesel performance bug and saw the possibilities. Working at one of diesel motorsport’s hubs at Fleece Performance Engineering at the time of the build, and now as a machinist for Neturen USA, the 21-year-old Casstevens well knew the potential inside his Duramax, and the idea of a 1,000hp street truck was too much temptation to pass up. With the help of several of the industry’s top shops and their best components, he set out to overhaul his daily driver into a road warrior.

After Casstevens initially did his exhaust work and a tune, he felt compelled to give the truck a little more. Once he had bolted on a stock-appearing Fleece Cheetah turbo, upgraded CP3, and new injectors, he realized he was going to have to bolster his stock Allison transmission to handle the power he was making with the upgraded Duramax.

Jacob Richards at Fleece helped Casstevens tear into the transmission to install a SunCoast Diesel 6Pac kit with Raybestos clutches, Transgo Jr. shift kit, a SunCoast Diesel 1058 billet triple-disc torque converter, Fleece Performance AlliLocker, and Merchant Automotive’s Pump Rub upgrade and transfer case brace. With his newly rebuilt transmission, the truck seemed like a complete build—until Richards said, “You should be good to go now unless you want to build the motor.” All it took was that seed of an idea to get Casstevens’ mind churning, envisioning a 1,000-horsepower street beast.

Soon Casstevens was talking to Chase Fleece and LJ Benshoof and Greg Lossi from Freedom Racing Engines to get the process started building his block. Using a core LBZ block as a starting point, the team at FRE was set to machine and build the short block. With a 0.020-over engine bore, cylinder heads milled with a competition valve job, bronze valve guides, FPE max life PSI springs, Chromoly retainers and keepers, Trend Performance Stage 3 push rods, CP-Carrillo connecting rods, Mahle Motorsport pistons, keyed and polished crank, SoCal Diesel 3388 cam, ARP main bolts and head studs with Grade C head gaskets, and all-new Clevite internal bearings, this LBZ was ready to breathe fire.

Back at Fleece Performance, Casstevens and some of the guys in the shop helped pull some long nights assembling the engine and installing the new heart in the ’07’s engine bay. Casstevens and the Fleece team further tightened up the Duramax with an ATI SuperDamper, new oil pump, and oil cooler, PPE Power exhaust manifolds and up-pipes, ATS Diesel dual pump kit with twin Fleece PowerFlo 750 10mm CP3s, PureFlow AirDog 200 4G fuel system, Banks Power Intercooler, and a SunCoast billet flexplate. Then they bolted the engine in place with a set of Merchant Automotive engine mounts. Expelling the fumes from the beast of an engine is a 5-inch JAMO exhaust system with a 6-inch tip. But even the built engine and single S366 turbocharger weren’t enough to quench Casstevens’ thirst for more power.

The next stop on the road to glory was Seth Wallace and Jake Bells of BOFA (Build Overhaul Fabricate Anything) Performance in Fairmount, Indiana, to custom build a compound turbo setup for his GMC. This would be BOFA’s first kit for the Duramax powerplant, but they didn’t back down from the challenge. After tooling and retooling their fabrication, the crew was able to craft a sleek and powerful compound setup, sporting the S366 turbo as well as an S480. Casstevens’ attention to detail shined as he made sure to dress up the upgraded engine components in an electric Illusion Blueberry powder coat finish by Shane Marshell at PCT Coatings tied in throughout the engine bay. With an expert tune by Brayden Fleece, this LBZ was set to top some charts.

Later, Casstevens upgraded his transmission further to keep up with the power with SunCoast billet input, output, and intermediate shafts, billet C2 and P2 hubs modified P1 sun gear, and swapped to a SunCoast 1053 torque converter for a higher rpm stall speed. With this configuration, Casstevens was able to put down an impressive 950 horsepower and 1,765 lb-ft of torque in his street-driving Duramax. And with some even more aggressive tunes loaded now, he plans to break that coveted 1,000-horsepower mark next time he straps the truck down to a dyno.

With all that power coursing through the veins of the Sierra, Casstevens had to focus on getting it to the street and keeping it there. To counter a weak point often found in powerful GMs, Casstevens installed Fleece Performance tie-rod sleeves. Tightening up the performance truck’s ride are the two-inch Belltech drop shackles, Bilstein 5100 front shocks and steering stabilizer, Caltrac traction bars, and the removal of the rear overload springs. Hostile Havoc 20-inch wheels were selected and paired with 305/50 Nitto 420s for grip down the road.

The focus of the build had been to cram immense power into a streetable machine, so when it came to aesthetics, Casstevens opted for a subtle, sleeper exterior and comfortable interior. Spencer Baledge in Alexandria, Indiana, helped color-match the Silver Birch factory paint into the mirrors, handles, and bumper plastics for a sleek custom look. A billet aluminum grille with the GMC logo removed, aftermarket headlights, and tinting on all three brake lights added some subtle touches to catch your eye. Inside, the factory gray leather remains with the only visible modifications being the AutoMeter A-pillar gauge pod with Ultra-Lite II gauges and an Edge Products tuner overhead. Audible customization comes from a JL Audio 6W3 sub replacing the factory Bose model inside the center console and a JL Audio 200-watt amp tied into the sound system.

All it took was that first upgrade and a little encouragement and Casstevens caught the performance bug. Even with a lofty goal, he was able to pull together his dream truck with help from friends at Fleece Performance Engineering, BOFA Performance, Freedom Racing Engines, and his brother Jarren  Casstevens. Living up to the goal, Casstevens 2007 GMC Sierra 2500 rides like a daily driver—that is, until you mash the throttle and let the beast come to life. Continuing to prove it can take the street or the track, on a recent 200-mile trip with the nearly 1,000-horsepower machine, it averaged 19 mpg. Casstevens truly built an awesome diesel truck.

FREQUENTLY ASKED QUESTIONS

What specific upgrades and aftermarket parts were used in the 6.6L LB7 engine build?

Upgrades and Aftermarket Parts in the 6.6L LB7 Engine Build

The 6.6L LB7 engine build is a masterpiece of engineering, featuring a range of specific upgrades and aftermarket components designed for enhanced performance and durability.

Internal Enhancements:

• Pistons and Rods: The engine is enhanced with Mahle Motorsport pistons that are .020″ over, paired with Carrillo rods for added strength.
• Cylinder Heads: Ported and polished cylinder heads are equipped with COMP Cams valve springs and unique threaded injector cups. This setup is secured tightly in place with ultra-durable ARP fasteners.
• Camshaft and Valvetrain: A Stage 2 camshaft from Extreme Engine Development manages the intake and exhaust valves. It uses TTS chromoly pushrods to ensure reliable performance.

Crankshaft and Exhaust Components:

• Vibration Dampening: An ATI damper is attached to the crank’s front to minimize vibrations.
• Exhaust System: The flow of exhaust gases is optimized using PPE exhaust manifolds and accompanying stainless steel up-pipes. An innovative PPE oil pan, known for its efficient draining and heat dissipation, complements the setup.

Fuel and Air System:

• Fuel Delivery: The engine benefits from a dual CP3 fuel kit that precisely meters fuel delivery, in conjunction with high-capacity Lincoln Diesel Specialties injectors and a sophisticated FASS fuel system.
• Forced Induction: Performance is bolstered by a compound turbo system featuring an S475 turbo for one stage and a BD Super Max S364.5 SX-E turbo for the other.

Cooling and Airflow:

• Intercooling System: A BD Xtruded intercooler efficiently cools the charged air before it reaches the engine, with turbo piping expertly fabricated by Black Sheep Industries ensuring optimal airflow.

These thoughtfully selected upgrades and aftermarket parts come together to transform the 6.6L LB7 engine into a powerhouse, pushing boundaries of performance and reliability.

How does the fuel and air system contribute to the power output of Bryan Woitas’ engine?

How the Fuel and Air System Boosts Bryan Woitas’ Engine Power

Bryan Woitas’ engine owes much of its impressive power to its finely tuned fuel and air systems. Let’s break down how each component plays a crucial role:

Fuel System Enhancements

1. Precision Fuel Delivery: The engine benefits from a dual fueler system, ensuring an optimal fuel flow that supports high power demands. This setup precisely calibrates the fuel amount, maximizing efficiency and performance.
2. High-Performance Injectors: The use of injectors that deliver 100% more fuel than standard models allows for an increased volume of fuel. This enhanced volume ensures the engine can sustain higher power levels.
3. Advanced Fuel Filtration and Pumping: A comprehensive fuel system, complete with advanced filters and pumps, ensures a clean and consistent fuel supply. This reduces the risk of impurities affecting performance and keeps the engine at peak power.

Air System Innovations

1. Compound Turbocharging: The engine features a two-stage turbo setup. The first stage is managed by a large turbocharger that begins the compression process, while a secondary turbocharger takes over for further compression.
2. Intercooler Efficiency: Prior to entering the engine and combustion chamber, the compressed air is cooled by an efficient intercooler. This cooling process increases air density, ensuring more oxygen-rich air is available for combustion.
3. Custom Turbo Piping: Expertly fabricated turbo piping guides the air smoothly into the engine, minimizing turbulence and optimizing airflow for maximum power output.

Together, these advanced fuel and air systems create a robust setup that significantly boosts the engine’s power, allowing it to perform at its absolute best.

What challenges did Bryan Woitas face while building his 1,000-horsepower LB7 Duramax engine?

The Challenges of Bryan Woitas in Building His 1,000-Horsepower Duramax Engine

Building a powerful 1,000-horsepower LB7 Duramax engine was no easy feat for Bryan Woitas. His journey was marked by several formidable challenges that tested his dedication and resilience.

The Initial Bite of the Diesel Power Bug

Woitas initially ventured into diesel power enhancements with some straightforward upgrades to his daily vehicle. This included fuel system modifications and installing larger injectors. While these enhancements turned his Chevrolet Silverado 2500 HD into a competitive race-ready machine, they also marked the beginning of numerous technical challenges.

Wear and Tear from Racing

After four years of relentless competition in local diesel events, the strain on his Duramax began to show. The high-stakes environment of racing subjected the vehicle to extreme conditions, leading to mechanical failures.

A Devastating Mechanical Breakdown

One of the most significant setbacks was when the original factory LB7 engine suffered catastrophic damage, with a connecting rod breaking and exiting the block. This incident not only halted Woitas’ racing endeavors but also meant a significant setback in terms of time and finances.

Turning Setbacks into Opportunities

Despite this severe blow, Woitas saw it as a chance for reinvention. Faced with the daunting task of rebuilding the engine, he took on the challenge with renewed determination. The process demanded countless hours of labor and technical expertise but ultimately led to the creation of a more robust and powerful machine.

Through perseverance and a commitment to overcoming each obstacle, Bryan Woitas transformed his setbacks into the stepping stones that helped him achieve his dream of a powerful 1,000-horsepower engine.

How did Bryan Woitas become interested in building high-performance diesel engines?

Bryan Woitas developed a passion for building high-performance diesel engines after he began modifying his everyday vehicle with some basic upgrades. As he experimented with increasing the power output, he became fascinated by the potential and capabilities of diesel technology. This hands-on experience sparked his interest and led him to dive deeper into the world of diesel performance, ultimately fueling his enthusiasm for crafting high-performance diesel engines.

What type of events did Bryan Woitas participate in with his modified Chevrolet Silverado 2500 HD?

Bryan Woitas took part in regional diesel competitions with his customized Chevrolet Silverado 2500 HD. After several years of participation in these intense events, the strain began to show on the vehicle.

What inspired Bryan Woitas to rebuild his engine after experiencing mechanical failure?

When Bryan Woitas faced a significant mechanical failure, with a rod catastrophically exiting the engine block, it temporarily sidelined his vehicle. This unexpected incident served as a catalyst for change. Instead of seeing it as merely an obstacle, Bryan was inspired to undertake a complete engine rebuild. The experience became an opportunity for him to meticulously reconstruct the engine, envisioning a fresh start by working from his own garage.

How long did it take Bryan Woitas to complete his high-powered Duramax engine project?

Bryan Woitas spent eight years pouring his effort, dedication, and perseverance into creating his ultimate high-powered Duramax engine.

What are some examples of other high-performance diesel engines discussed in the related articles?

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