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'Killing a Duramax' Gale Banks YouTube series methodically tunes a diesel to death

Learning or perfecting a skill by watching YouTube videos is known as attending YouTube University. GM Authority picked up on one of the video site's more fascinating courses, hosted by Gale Banks; in a fair world, he should be referred to as Professor Banks when it comes to diesel engines and truck tuning. A few months after GM introduced the updated L5P 6.6-liter Duramax diesel V8 in the 2020 Chevrolet Silverado HD and GMC Sierra HD that ships with 454 horsepower and 910 pound-feet of torque, Banks decided he wanted to methodically tune the engine to death. The purpose of the resulting series, called "Killing a Duramax," is to push more power out of the engine in order to discover which parts break and when — or, as Banks puts it, force-feed the Duramax "until the crank hits the street and the heads hit the hood." With that knowledge, Banks can figure out all the weak points on his way to building what he calls a "Superturbo," that being a supercharged, twin-turbo race engine with more than 1,000 hp. What makes the series fascinating is Banks' knowledge, paired with the company's comprehensive iDash engine monitoring system that keeps tabs on a glut of parameters every step of the way. So for instance, you get Banks explaining the differences between inches of mercury and barometric pressure, how those are different from the water content of the air measured in grains, then showing those readouts on the iDash, then explaining in detail how they affect the air density in the Duramax system. The stock Borg-Warner variable turbo gets a lot of airtime — Banks accuses it of being "out to lunch" because he feels it's the weakest link on the engine. That turns into a turbo teardown and a deep explanation of performance pitfalls, such as when air pressure on the turbine begins to diverge from the boost pressure coming from the compressor. Banks says he can keep close tabs on where power's coming from, because the iDash monitors the horsepower contribution provided by the ambient air, the turbo, and the intercooler separately. The major changes so far are a stouter Precision 7675 turbo and TurboSmart wastegate (episode 5), a twin intake (episode 6), a custom liquid-cooled intercooler from a marine engine, a new GM oil cooler and synthetic oil (episode 10), and new injectors (episode 11).

2019 GMC Sierra carbon fiber bed: How it's made

FORT WAYNE, Ind. — The redesigned 2019 GMC Sierra has some pretty nifty features, and the one that has had the most attention is the MultiPro flipping and folding tailgate. But the Sierra also features the first-of-its-kind carbon fiber truck bed. It's interesting, of course, for its capabilities, such as being 62 pounds lighter than the all-steel box. It even adds more cargo volume since the material can be assembled and shaped differently from steel. As it turns out, the assembly process is cool, too, which we learned when GMC invited us to see the beds being made. Every GMC carbon fiber bed starts out as perfectly flat sheets of thermoplastic carbon fiber. The sheets consist of a mix of fibers and resins, a bit like the molded carbon fiber parts Lamborghini uses. The sheets are manufactured by Japanese company Teijin, which collaborated with GMC to develop the bed. They're all delivered to Continental Structural Plastics (CSP) in Fort Wayne, Ind., for construction into the actual bed. The company, a subsidiary of Teijin, makes a wide variety of composite and plastic parts for the car industry, including body panels for the C7 Chevy Corvette. The rectangular sheets are cut to shape and stacked up at a giant stamping press. Robots pick up sheets and slide them onto a conveyor that goes into a large oven. The heat softens the parts so they can be stamped. The large primary bed parts such as the base are stamped by CSP's enormous 3,600-ton press, and the smaller ones go through a 1,000-ton press. Each press can do different parts using different stamping dies, and CSP switches between dies to produce different batches of parts. After stamping, the parts roll out mostly ready for assembly, but there are rough edges that are trimmed off by water-jet cutters. These cutting machines also create holes for fasteners and for parts such as tie-down hooks and lights. The stamping process also provides the carbon fiber bed with a unique Easter egg. On the bottom of the base of the bed, there are two words: "Connors Way." This is a tribute to Tim Connors, who was the chief engineer of manufacturing at GM and a strong proponent of the carbon fiber bed. He was tragically killed in a motorcycle crash a few years ago. The words were added to honor him, and they were fortunately approved for production. There are some components to the bed that aren't stamped from the flat sheets of material.

GM raises 2023 guidance on strong sales, higher profits

General Motors beat first-quarter profit estimates and raised its full-year earnings and cash-flow guidance after vehicle demand at the start of the year surpassed expectations. Its shares rose in premarket trading. GM made $2.21 a share in adjusted profit in the first quarter, compared to a consensus forecast of $1.72 a share. Revenue rose 11% to $39.99 billion, it said Tuesday, which was more than the $39.24 billion analysts expected. The stronger results stem from rising sales in the US, even in the face of higher interest rates and inflation. GM executives said demand was strong enough to revise 2023 guidance upward, boosting profit estimates for the year by $500 million to between $11 billion and $13 billion. “We did it with strong production and inventory discipline and consistent pricing,” GM Chief Financial Officer Paul Jacobson said on a call with journalists. “All in all, weÂ’re feeling confident about 2023.” The Detroit automaker raised per-share full-year guidance to between $6.35 and $7.35, up from $6 to $7 a share, and said free cash flow would also increase by $500 million to a range of $5.5 billion to $7.5 billion.  GMÂ’s shares pared a gain of as much as 4.4% before the start of regular trading Tuesday, rising 3.5% to $35.50 as of 6:55 a.m. in New York. The stock was up 1.9% for the year as of the close on Monday.  North American Strength The automakerÂ’s sales were particularly strong in North America, where first-quarter earnings rose before interest and taxes rose to $3.6 billion. Vehicle sales rose 18% to 707,000 in the region. Jacobson said the company originally expected to sell 15 million vehicles in the US this year, slightly less than the 15.5 million annualized rate automakers foresaw in the first quarter. North American demand was enough to offset a weak performance in China, GMÂ’s second-largest market. The automaker continues to struggle in the country, where its vehicle sales fell 25% to 462,000 vehicles in the quarter. Profits from its joint ventures in the market slumped 65% to $83 million.  The market has struggled overall in the wake of Covid-19 restrictions and foreign automakers have had to overcome a growing preference for Chinese brands by competing on price, squeezing profit margins. The situation in China probably wonÂ’t significantly improve until the second half of the year, according to Jacobson. GM remains on target to sell 150,000 electric vehicles this year, the CFO said.