3,300 hp on the dyno, ultra-clean diesel swaps, and a sprawling show ‘n shine highlight Wehrli Custom Fabrication’s biennial celebration.
Arguably no other company in the diesel industry has experienced the kind of exponential growth Wehrli Custom Fabrication has. High quality, precise fitment products, top-tier drive-in service, powder coating, CNC machining, endless product development, and product support for everything from diesel trucks to Jeeps and even side-by-sides has led to constant expansion for the northern Illinois company. In just 14 years of existence, Wehrli Custom Fabrication has outgrown four different facilities, with its fifth (and hopefully its final) destination now located in DeKalb, Illinois. The current, 112,000 square-foot mecca also serves as the site of its biennial Open House.
Back in 2020, Wehrli hosted a truck pull on the land where its new building now exists. For 2022, the first open house and truck show was held to introduce the world to the state-of-the-art facility. On Saturday, October 5, 2024, the open house and show ‘n shine expanded to include a dyno competition—and the industry standard SuperFlow from the Northwest Dyno Series was on hand, measuring horsepower. Before the day was through, spectators were witness to a 3,337hp effort from Greg A., the cleanest show trucks in the Midwest, and some of the best-executed diesel swaps we’ve ever seen. Trust us, this event is worth your time!
Greg Alberalla is no stranger to the Northwest Dyno Series’ SuperFlow, having both toasted an engine on it in 2023 and made 3,059 hp aboard it back in the spring. This time, thankfully there were no fireworks, just a new personal record for Greg A. and his ‘05 Dodge: 3,337 hp! We’d say he’s mastered the most recognizable (and unforgiving) load cell dyno in the industry—and this may only be the beginning of bigger things to come… Photo courtesy of Don Schroeder from D3 Photography.Greg A.’s 3,337hp rip on the rollers was made possible thanks to a Freedom Racing Engines 6.7L-based Cummins, fueling from S&S Diesel Motorsport, a perfectly timed hit of nitrous, and MoTeC stand-alone control and diesel-specific, S&S firmware. The number was also squeezed through a Loganbuilt 48RE transmission. Last but not least, the lead wrench on Greg A.’s ’05 is none other than Michael Cordova, driver of the quickest (and fastest) diesel in the world. How’s that for a winning combination!Fresh off a 2,261-rwhp fuel-only performance the weekend before (at Mid Michigan Mayhem 2K24), all indications were that DHD’s “Last Minute Hooker” would put up a big number. After all, this time the boys from Harbor Beach, Michigan brought nitrous to the party. We caught up with driver Tyler Burkhard while he was running lines to the five (5) Nitrous Express solenoids along the firewall. “The plan is to not blow it up,” he said, reminding us that they just got the Duramax back together and were more or less collecting data on their dyno tour.Beneath the hulking 91mm Precision atmosphere chargers and the 88mm Precision under them, the DHD-built, 460 ci Duramax boasts an LSM billet-aluminum block, 400-percent over, LLY-based Exergy Performance injectors and dual 14mm reverse rotation CP3’s, and a Bosch Motorsport MS15.1/Power Box PBX90 combination for full vehicle control. The turbo arrangement—which is far different from the single 106mm unit they drag race with—is solely employed for dyno purposes. The modular triple-turbo idea, originally drawn up by family friend and founder and CEO at Sidetracked Productions, Charles Poosch, can be installed and/or uninstalled in minutes.After the first swing on the dyno, the guys at DHD knew something was wrong. Looking at the data, rail pressure had instantly fallen from 30,000 to 15,000-psi during the hit, which limited the truck to 1,583 hp. Believing they’d lost a CP3 (and hopefully only spun the gear rather than had a pump come apart), team DHD called it a day and unstrapped the truck. Unfortunately, setbacks are part of making big horsepower. What we found interesting was that the triple-turbos still produced 113-psi of boost (and 132-psi of drive). DHD’s Morey Logue tells us that, with healthy rail pressure, they max out the 140-psi boost sensor…Spencer Schulte, who trekked all the way from Wilder, Idaho, was the first competitor to take the stage in the Unlimited class. Well-versed on the Northwest Dyno Series’ SuperFlow, and having made 2,638 hp on it over the summer, Spencer and his third-gen made 2,454 hp before white smoke began to leave the hood stack. A snapped turbine shaft on the manifold turbo proved to be the culprit, but Spencer still walked away with the second highest number of the day.A reputable dyno is a great tool for testing the limitations of parts. Take Dane Crowder’s ’17 King Ranch F-250 for example, a truck that’d been outfitted with an S&S Diesel Motorsport DCR conversion and 100-percent over injectors. Topped off with a 64/66mm drop-in VGT from Precision, not only was it the perfect candidate for the Small Single turbo class at the WC Fab Open House, but it was also an ideal truck for finding out what kind of horsepower the DCR pump will support. With a 699 hp dyno sheet, it’s proof that Dane’s combination of parts can support roughly 700-rwhp. And oh by the way…the late-model Super Duty took top honors in its class.Speaking of the DCR pump, S&S Diesel Motorsport set up shop inside the friendly confines of Wehrli Custom Fabrication and had its CP4 to DCR conversion kit on display. The plug-and-play solution for the 6.7L Power Stroke’s biggest weak link (a self-destructing CP4.2 high-pressure fuel pump) has proven to be a huge hit in the industry, with 16,000 kits (and counting) sold so far. The two-piston DCR pump, which was co-developed between S&S and PurePower Technologies, flows 25-percent more fuel than a factory Bosch CP4.2—hence its ability to support larger injectors and 700-rwhp, as shown above.When you factor in a sprawling (indoor and outdoor) show ‘n shine, vendor booths strategically scattered throughout, raffles, a live auction (which benefits local students interested in pursuing a career in the trades through the Wehrli Custom Fabrication Scholarship Fund), food trucks, the mullet competition (yes, you read that correctly), a bounce house and kiddie pedal pulls for the youngsters, and combine it all with free admission, it’s no wonder hundreds showed up to the 2024 Wehrli Custom Fabrication Open House. As you can see (aside from the lone Blue Oval pictured), the Duramax crowd was well-represented in the show ‘n shine this year.Keith Porter’s ’52 Chevrolet 3100 is like nothing you’ve ever seen. On the outside, its original body panels and preserved Patina suggest there is nothing exotic or over the top. But on the inside, under the hood, and in the bed it’s full of surprises. For starters, an L5P Duramax and 10-speed Allison combination were made to work thanks to a MoTeC stand-along ECU with S&S firmware, and endless calibration support from S&S’s Andre Dusek. Out back, a Corvette rear end with 2.56 gears allows the Duramax/10-speed combo to turn 1,200 rpm at highway cruising speed—part of the reason Keith’s 2,800-pound truck gets 46-mpg!In addition to dozens of award-worthy late-model Chevrolet’s and GMC’s, there was no shortage of GM classics entered in the show ‘n shine. Jaw droppingly clean, this ’68 Suburban belongs to Dan Doty of 3-D Auto Repair in nearby Cortland, Illinois. It was Duramax swapped at Wehrli Custom Fabrication—complete with the company’s top outlet billet thermostat housing and upper radiator hose, high-flow intake bundle kit, and brake master cylinder reservoir, to name a few items—and the LBZ is backed by a six-speed Allison 1000. The traction bars, lift pump install, custom aluminum fuel tank, and power distribution center work was also carried out at WC Fab, while the Suburban was primered and painted locally at Marty & Sons Body Shop Inc.We didn’t think Aaron West’s Dodge sounded like a VE-pumped 12-valve when we came across it waiting in line to dyno. Sure enough, a common-rail 5.9L Cummins lurks under the hood, as well as a third-gen chassis underneath the Ram 150 body. It’s also benefiting from a full manual valve body 48RE. Aaron took top honors in the Large Single turbo class, making 930 hp on fuel. With a bit of nitrous sprinkled in, he expects the truck to lay down 1,200 hp.If you don’t know Dan Clarke, you’ve probably heard of his company, Dan’s Diesel Performance, and they know a thing or two about making horsepower. Dan entered his LB7 Duramax-powered Sierra in the Big Twin turbo category and walked away the winner. The compound turbo’d, standard cab GMC (nicknamed “Rocket”) laid down 1,056 hp, and it did it with a factory-based, drop-in style charger in the lifter valley. For fuel, the truck packs a potent punch thanks to 400-percent over injectors and a pair of 12mm stroker CP3’s.For growing businesses, expansion never stops. The latest addition at Wehrli Custom Fabrication is its engine dyno. We poked our head in the company’s brand-new dyno cell for a few photos and noticed this dual CP3, Waterman lift pump-fed Duramax occupying the space. Without question, this Dynomite Dynamometer will take WC Fab’s competition engine game to the next level. Additionally, it may serve to help them tweak their existing product lines to free up even more horsepower. Stay tuned for more on the latest tool in the Wehrli arsenal…This rolling chassis and engine combination might be the nicest we’ve ever laid eyes on. Imagine winning a “Best Dodge” show ‘n shine award without even having a body present… If you ask us, it’s a shame a body will cover most of this up, but you can bet that Dunwiddie Diesel (@lanced.99) won’t skimp on the body work. The gloss painted masterpiece is highlighted by a VP44-fueled 24-valve Cummins sporting a compound turbo arrangement. Perhaps Lance should call the truck “Attention to Detail?”With all of its foot traffic, a show like the WC Fab Open House is a great place to sell a truck. We’re not sure if Bret Kehl found a buyer for his shortbed Chevy at the show, but dozens of passersby were giving it attention. Bret’s rear-wheel drive ’01 Silverado 2500 boasts a built Duramax and Allison, compound turbos, a four-link rear suspension, and 1,200 hp. We also noticed the hidden roll bar inside the impeccably clean cab. According to Bret, the blacked out Bow Tie has been as quick as 9.96 in the quarter-mile, and as fast as 140 mph.It’s hard to beat a square body, and the WC Fab Open House was jampacked with them—perhaps none of them nicer than Jason Wehrli’s own ‘87 K30. Duramax swapped, fitted with a T-4 S300, and backed by a ZF-6 manual transmission, this old-school Chevrolet epitomizes what the folks at Wehrli are capable of. In fact, it’s one of the projects that inspired them to gauge interest in offering a square body kit to help DIY’ers perform their own Duramax conversions. The aforementioned kit would come with a bolt-in engine mount (which welds to your square body’s core support), a fabricated transmission cross member that allows you to run either a Duramax-Allison or Duramax-ZF-6 combination, and a big-block style aluminum radiator with dual fans.
