Built for Power, Ready for One Lucky Winner
For those who haven’t been keeping up (and seriously, why not?), here’s the scoop: KC Turbos is giving away its legendary 7.3L Ford F-250 Super Duty. This truck has played a vital role in our fleet, serving as a testbed for product development and CARB certification. But instead of selling it off, we’re handing over the keys to one lucky winner. And the best part? Even if you don’t win, we’re showing you exactly how to build your own 7.3L just like it.
From Stock to Show-Stopper
Before it leaves our shop, this F-250 is getting a full transformation. After listening to our fans, we knew the build needed to preserve the 7.3L’s iconic feel—an OEM+ style resto-mod. That meant a modest leveling kit with 35-inch tires (no sky-high lifts or blingy wheels), and a focus on clean, reliable performance.
The target? A solid 500 horsepower at the wheels, perfect for towing and everyday power. To make it happen, we installed our all-new KC300x Gen 3 Stage 2 turbo, Full Force 238/80 injectors, and all the supporting upgrades needed for long-term reliability and performance. This isn’t a high-strung dyno queen—we built it to last.
Chasing 500+ Horsepower
By Episode 5 of the build series, we hit our goal: 505 hp to the wheels. This was achieved with the help of an AirDog lift pump, CNC Diesel Fabrication high-pressure oil pump, and a Driven Diesel regulated return system. But we knew there was more potential.
Our first move? We removed the stock muffler—not expecting much, but the results shocked us: a 22 hp and 45 lb-ft torque increase. At 2,500 RPM, the gains peaked at 35 hp and 70 lb-ft of torque. Years of carbon and soot buildup had likely turned the muffler into a major bottleneck.
We then replaced the entire exhaust system with a 5-inch turbo-back from MBRP—but to our surprise, it yielded no measurable gains. No extra boost, torque, or power, just a better exhaust note.
Wait—Adding Restrictions Helped?
With airflow still not where we wanted, we tested the opposite approach: we reinstalled a fresh S&B cold air intake system. Surprisingly, horsepower increased. We suspect the intake delivered cooler, smoother airflow, and it showed with a quicker spool and 6 psi more boost—reaching up to 53 psi at peak effort.
Live Tuning Makes All the Difference
To refine the setup, tuning expert Andrew Arthur from AA Design & Performance came in for live tuning. By adjusting injection control pressure (ICP), thanks to the high-output CNC HPOP, Andrew unlocked even more power.
Live tuning goes far beyond just horsepower. It allows full control over throttle response, shift points, torque converter lockup, and even smoke output—truly personalizing how the truck behaves. After final tuning, we took the truck out with Andrew and Bill Cohron of Power Hungry Performance, a true 7.3L legend. Let’s just say the burnout left everyone grinning—and slightly terrified.
Data-Driven Results
Every good build starts with solid data. Our first mod on this truck? An Edge CTS3 monitor with the EAS system, allowing us to track everything from fuel pressure to exhaust temps to boost levels. This data was essential throughout the build to ensure every upgrade delivered real results.
Final Touches
Now that the powertrain is dialed in, we’re giving the truck a visual refresh with updated headlights and grille—subtle, clean, and true to the original. A 6.0L Harley front end swap was considered, but we ultimately chose timeless, period-correct updates to maintain the truck’s classic appeal.
Want In?
This isn’t just a showpiece—it’s a fully functional, street-ready powerhouse. Stay tuned as we finish the final touches and hand over the keys to one very lucky winner. In the meantime, you’ve got the full roadmap to build your own 7.3L beast, KC-style.