Double-Barrel Rail, New Products, and Development | Justin Norris S&S Diesel
Diesel Performance Podcast
Double-Barrel Rail, New Products, and Development | Justin Norris S&S Diesel Diesel Performance Podcast · Jul 6, 2026
Double-Barrel Rail, New Products, and Development | Justin Norris S&S Diesel

Annotations will appear as you listen

0:00
32:30
Double-Barrel Rail, New Products, and Development | Justin Norris S&S Diesel
Term

third gear

A car’s transmission has different gears, and “third gear” is one of them. When tuners talk about third gear for sled pulls, they mean they’re dialing in how the engine and power delivery feel while the truck is pulling in that gear.

Term

low sled pull tunes

“Low sled pull tunes” refers to diesel calibration strategies aimed at sled-pulling competition where the goal is strong torque and controllable power at lower speeds/gear ranges. These tunes are typically designed to manage traction and prevent bogging or excessive smoke while the puller is under heavy load.

Term

injectors

Injectors are the parts that spray fuel into the engine. In a diesel tune, controlling the injectors is a big deal because it determines how much fuel gets burned and when, which affects how the truck runs.

Term

injector output

Injector output is how much fuel the injector squirts into the engine each time it opens. If you turn it up, the engine can run more fuel, but the fuel system has to keep up so pressure doesn’t sag.

Term

double barrel fuel rail

A double barrel fuel rail is a modified fuel manifold for a diesel. It holds more pressurized fuel so the pressure doesn’t drop as much when the injectors open, helping the engine deliver the commanded fuel more accurately.

Term

injector open

“Injector open” is the time the injector is actively spraying fuel. If the fuel pressure is falling during that moment, the engine may not get the exact fuel amount it expects.

Term

microseconds

Microseconds are tiny slices of time—one-millionth of a second. The injectors open and close so fast that pressure changes during that brief window can change how much fuel the engine gets.

Term

rail pressure control

This is how the engine keeps the diesel fuel pressure at the right level. If the pressure is steady, the engine can inject fuel more consistently, which helps performance and smoothness.

Term

turbochargers

A turbocharger uses exhaust gases to force more air into the engine. More air helps the engine burn more fuel, which is why tuners chase turbo performance for extra power.

Term

dinotesting

Dinotesting is testing a car on a dyno to measure power. They’re saying they haven’t collected dyno results yet, so they can’t prove any horsepower increase.

Term

UCC

UCC is where Tim Moore previously made that big horsepower number. It’s a specific competition/testing event name in the diesel world.

Term

240 MPa

240 MPa is the fuel pressure they used during testing. It’s extremely high pressure, meant to simulate the “full tilt” conditions competition diesels are built for.

Term

double barrel rail

This is a modified fuel rail for a diesel engine. The idea is that it holds more high-pressure fuel so the injectors can deliver more fuel when you’re chasing big power.

Term

engine dyno

An engine dyno is a machine that runs an engine and measures how much power it makes. “Back-to-back” testing means comparing two parts by testing them one after the other on the same setup so the results are fair.

Term

durability testing

Durability testing checks whether a part can survive repeated use. It’s about long-term toughness, not just short-term performance.

Term

3000 bar

“Bar” measures pressure. 3000 bar is a very high pressure number used to stress-test diesel fuel system parts so you know they can handle extreme conditions.

Term

OE

OE means “original equipment,” referring to parts and engineering that match what the vehicle manufacturer designed and supplied. When a company says it builds “as close to OE as possible,” it typically means it targets similar materials, tolerances, and manufacturing methods to maintain reliability.

Company

Cummins

Cummins is a big diesel engine company, especially for trucks. Saying they have Cummins engineers suggests the team understands diesel engines and fuel systems well.

Company

Bosch

Bosch is a well-known auto parts company. If the team includes former Bosch engineers, it usually means they have deep experience with diesel fuel systems.

Term

injector ports drains

On some diesel fuel rails, there are drain passages near where the injector lines connect. If a connection leaks slightly, the drain gives that fuel a safe path out so pressure doesn’t keep building and cause the line to come loose or break.

Term

dual feeding

Dual feeding is when you route fuel so two sides/components get fuel at the same time. The idea is to support more fuel flow for higher power, and the host is saying the stock setup doesn’t handle that well.

Term

CP3

CP3 is a common name for a diesel high-pressure fuel pump. In this discussion, they’re talking about using CP3 pumps together to feed fuel for more power, and how there’s a limit to how much fuel the system can provide.

Term

accumulator

An accumulator is extra fuel volume used to smooth out pressure swings. When injectors open, pressure can dip and recover—this helps make that behavior steadier.

Term

pulsations

Pulsations are quick “waves” in fuel pressure caused by the injectors firing. Smoothing them out helps the engine (and testing) behave more consistently.

Term

auxiliary ports

Auxiliary ports are extra connection points on the fuel rail. They’re handy for adding tools like a pressure sensor or safety valve.

Term

super stock engine

A super stock engine is a more extreme competition-style build. The idea is that only very high-fuel-demand setups would need extra fuel pumps.

Term

pressure relief valve

A pressure relief valve is a safety valve that opens if fuel pressure gets too high. It helps protect the system from overpressure.

Term

pressure sensor

A pressure sensor measures how much pressure is in the fuel line. Putting it in the right spot helps you see what’s really happening during tuning/testing.

Term

EGTs

EGTs means exhaust gas temperatures. If they get too hot, it can stress the engine and exhaust parts, so tuners watch them to avoid damage.

Term

transmission safety

Transmission safety means making sure the gearbox can handle the extra torque from a tune. If the tune pushes it too hard, it can overheat or wear out faster.

Term

DPF

DPF means diesel particulate filter. It’s a part that catches soot from a diesel engine, and it has to stay working correctly—otherwise emissions systems can get damaged or clogged.

Term

EGR

EGR is exhaust gas recirculation. It helps control pollution by sending some exhaust back into the engine, and tuning has to account for it so the system doesn’t get overwhelmed or damaged.

Term

calibrations

Calibrations are the computer settings for the engine. They control things like fueling and how the emissions parts are managed, which is why tuning can change both power and reliability.

Term

chassis dyno

A chassis dyno tests the vehicle on rollers. It helps tuners see how the car behaves under load, which is important for drivability and safety.

Term

CP4 metal

This means tiny metal debris coming from a high-pressure fuel pump. If it gets into the rest of the fuel system, it can cause expensive damage, so the product is meant to prevent that from happening.

Term

fuel filter housing

The fuel filter housing is the part that holds the fuel filter and keeps fuel from leaking around it. If it cracks, fuel can leak under the hood, which is why they’re upgrading it.

Car

6-7 power strokes

They’re talking about Ford’s 6.7-liter diesel engine. They say a known problem on these engines is the fuel filter housing can crack and start leaking fuel.

Term

billet aluminum

Billet aluminum means the part is made from a solid piece of aluminum and machined into shape. The point is it’s stronger and less likely to crack than plastic, so it helps stop leaks.

Term

factory filtration

Factory filtration is how the car’s fuel system is originally set up to filter out dirt and debris. They’re saying their kit fixes leaks without making the filtration worse.

Term

4 micron absolute

This is a filter rating that tells you how small of particles the filter can catch. “4 micron” means it’s designed to trap very tiny stuff before it can move through the fuel system.

Term

99% efficiency

This number is how well the filter works. “99% efficiency” means it’s designed to catch almost everything it’s meant to catch.

Term

5 micron

This is another filter rating. “5 micron” means it’s designed to catch particles around that size, and the host is comparing it to a tighter (smaller) rating.

Term

fuel leak prevention kit

This is an aftermarket kit meant to stop fuel from leaking. The idea is to replace leak-prone parts so they don’t crack and fail with heat and time.

Term

aluminum fuel leak prevention fitting

It’s a replacement fuel fitting made from aluminum. Aluminum is less likely to crack than plastic, so it helps prevent fuel leaks over time.

Term

injector return fittings

These are the connections that send fuel back from the fuel injectors. If they crack, they can leak fuel, which is why people replace them with stronger parts.

Term

quick connect

A quick connect is a type of fitting that’s designed to be attached quickly. It helps you replace the old part without a lot of hassle.

Term

hose barb

A hose barb is a ridged piece that holds onto a rubber hose. It’s commonly used in fuel and vacuum lines because it helps keep the connection tight.

Ford F-250 through F-750 trucks
Car

Ford F-250 through F-750 trucks

These are Ford’s heavy-duty trucks (F-250 up to F-750). The episode is talking about a fuel-system kit made to fit those trucks for certain years.

Term

dipstick mount

It’s a bracket that holds the oil dipstick steady. If you add an aftermarket intake, the dipstick can end up in the wrong spot, so the mount keeps it from moving around and hitting nearby parts.

Term

filter head

The filter head is the part that holds the fuel filter in place. It’s part of the fuel system, and in this story it’s where the dipstick can end up interfering if you change the intake.

Term

direct drop-in

A direct drop-in means the part is designed to install without major changes. It’s supposed to fit like the factory part, but in this case some setups need an extra accessory to avoid interference.

Term

aftermarket intakes

Aftermarket intakes are replacement air intake parts you install instead of the factory setup. They can change where other components sit, so the dipstick may need a special mount to keep it from hitting nearby parts.

Concept

compatibility testing

Compatibility testing is the process of checking that a product works correctly across different vehicle configurations and common modifications. Here, the company delays launch while testing against different factory intake setups to ensure the parts work together without interference.

Term

fuel system

Your fuel system is everything that gets fuel from the tank to the engine, including pumps and filters. Keeping it clean matters because diesel engines can be sensitive to dirt.

Term

stage two filter

A stage two filter is an extra filter step that catches more dirt after the main filter. The point here is that if you bypass or change parts before it, you lose protection against debris.

Term

disaster prevention kit

A disaster prevention kit is an aftermarket set of parts meant to help avoid costly problems during an install or service. They’re saying this job is easier than that kind of install because it doesn’t require as much disassembly.

Term

plastic cup

The “plastic cup” is the factory part that holds the fuel filter in place. They removed it because it interfered with the filtration design they wanted to achieve.

Term

fueling quantity

Fueling quantity means how much fuel the engine gets during each injection. More fuel can make more power, but it has to be matched with the right amount of air so it burns cleanly.

BMW X5
Car

BMW X5

The BMW X5 is a luxury SUV. Here it’s mentioned because the speaker says there are fuel-system prevention kits available for certain diesel setups in the X5.

BMW 535S
Car

BMW 535S

BMW’s 5 Series is a common midsize sedan. In this conversation, “535s” is being used as an example of another diesel BMW that can be protected with a prevention kit.

EcoDiesel
Car

EcoDiesel

EcoDiesel is a diesel engine option used in some Jeep/Ram vehicles. They’re saying there are kits available to help prevent fuel-system problems on those diesels.

Term

flat tappet

A flat tappet is a type of engine cam/lifter contact design. In this context, it’s being mentioned as a durability upgrade that helps protect the engine from wear.

0:00
32:30