When Sam, the YouTuber behind @V-BELT and SON, bought his 6.7 Cummins seven years ago, he treated it like a daily driver: minimal mods, careful maintenance, and plenty of adventures. Over the years, the truck had seen a new Defender aluminum bumper and some rear airbags, but otherwise, it remained completely stock. Sam explains his approach:
“All I’ve ever done to this truck is the bumper and the airbags. That’s it. Everything else? Stock.”
Yet even a carefully maintained truck isn’t immune to hidden weak points. One small but critical part—the grid heater stud on the intake horn—can loosen over time and risk falling into the intake. Sam had read the horror stories and decided it was time to take action:
“I heard about some little stud falling off and going through your intake, and for some reason, the target’s number six cylinder. So, we’re going to be addressing that today.”
This upgrade wasn’t about chasing horsepower—it was about preventive care, reliability, and peace of mind. After more than 74,000 miles, the concern was real, and replacing the stock intake horn with a precision-machined billet aluminum 6.7 Cummins intake horn would remove the weak point while improving airflow and durability.
Unboxing the SPELAB Intake Horn
Sam captured his first impressions during unboxing:
“Wow, there’s actually just keep going… all of it, the gaskets, all the bolts… Not sure what those are for, but we got them. All kinds of just goodies here.”
The kit includes a billet aluminum intake horn, gaskets, bolts, and a grid heater delete segment. From an engineering perspective, the design is thoughtful: the airflow path is unobstructed, mounting points are reinforced, and thermal expansion tolerances are accounted for. This ensures a durable upgrade capable of handling years of vibration and thermal cycling while still integrating seamlessly with factory sensors and fuel rails.
The anodized billet aluminum looks sharp, and the kit includes every necessary component for a plug-and-play installation, reducing the chance of errors during assembly. Even small details, like plugs for unused ports, show attention to both function and reliability.
Installation: A Hands-On Review
Sam described the installation process as thorough but manageable:
“You actually got to take quite a bit of stuff off. The whole fuel rail and all that needs to come off. That’s where it’s not that much fun… But it’s time to shine. It’s time to get her done.”
Working around the EGR system and grid heater requires care:
“The EGR exhaust gas recirculator is a joke and a half of a deal… The grid heater is a big restrictor. The new Cummins doesn’t have that, but the old one… well, that’s where the problem lies.”
The stock intake horn’s grid heater creates a thermal bottleneck in the airflow, which, over time, can stress both the stud and the surrounding aluminum. By replacing the intake horn with a billet version, airflow is maximized, turbulence is reduced, and weak points like the stud are eliminated.
During the fuel rail and sensor removal, Sam emphasized attention to detail:
“It even came with all the plugs for the ports. I’m not using the 8-inch MBT stuff. So, we need to take this stuff off, need to take these studs off… Sensor comes off. 8mm all goes on to the new dog.”
Ensuring all components are properly reinstalled is critical. Any loose connections could compromise fuel pressure, sensor readings, or injector performance. The kit’s design anticipates these touchpoints, making assembly smoother and more reliable than generic replacements.
Comparing Stock vs. SPELAB
One of the most noticeable differences is the airflow path. Sam highlighted the contrast:
“Look at just the absolute difference in size right there… Pretty different. You can see right there where the black sit just backs up and goes around the corner on both sides. And this one utilizes all the surface area that is allowed. That’s why it’s got that big hole in the top and this long Allen for putting one of these suckers down in the bottom of it.”
By removing the center pillar and enlarging the passage, airflow is smoother and more efficient. While Sam wasn’t chasing peak horsepower, the design provides measurable low-RPM gains and reduced restriction, which helps with both engine breathing and thermal management. Analyzing performance return on investment confirms why this matters.
The billet intake horn also improves longevity. Aluminum dissipates heat better than the stock stamped steel or composite horn, reducing thermal stress on surrounding components and preventing long-term fatigue.
With the intake horn installed and everything tightened, Sam was ready to fire up the truck. “We’ve got zero restriction right here. Good deal,” he notes.
Now, with everything in place, the truck was ready for testing. The airflow improvement and grid heater deletion were immediately noticeable...
Post-Installation Performance
After the upgrade, Sam put the truck through its paces:
“It’s not a horsepower mod. It’s about knowing my engine is safe. That peace of mind is priceless.”
Even on extended road trips, the SPELAB intake horn performed flawlessly:
“We went on a 6 and 1/2 hour roundtrip… all systems go. No problems with the truck.”
The real value of this upgrade is durability and reliability. Preventing a catastrophic failure at 70,000+ miles preserves both engine health and the owner’s peace of mind. The airflow improvements are a secondary bonus, providing better efficiency and responsiveness at low RPMs.
2007-2018 Dodge Ram 2500/3500
Upgrade Your 6.7 Cummins Intake HornWhy This Upgrade Matters
- Eliminates the grid heater stud as a potential failure point
- Maximizes airflow through the intake manifold
- Maintains OEM sensor and fuel rail integration
- Improves thermal management and longevity
Sam’s case illustrates a common scenario: a mostly stock truck, maintained carefully, can still benefit from a preventive, precision-engineered upgrade. For owners concerned about long-term reliability, this is an investment in peace of mind rather than raw power.
FAQ – 6.7 Cummins SPELAB Intake Horn
Q: Do I need a tune to run the SPELAB intake horn?
A: No. This is a mechanical efficiency upgrade. The 6.7 Cummins ECU uses MAF and MAP sensors that automatically adjust to the cleaner airflow. No programmer is required.
Q: Will installing this intake horn affect my emissions system?
A: The kit is designed to maintain OEM sensor and fuel rail integration. While it deletes the internal grid heater stud as a weak point, it does not interfere with emissions compliance on trucks that still have active systems.
Q: Is this kit compatible with all 2007–2025 6.7 Cummins trucks?
A: Yes. The design covers both standard and high-output trucks in this range, ensuring a plug-and-play fit without modification.
Q: How difficult is installation for someone with basic mechanical skills?
A: Installation requires removing the intake horn, fuel rail, and sensors, which can be a moderate task. Sam noted it took a few hours, but with organized steps and following the included instructions, a careful DIYer can complete it successfully.
Q: Will I notice a performance difference after installation?
A: While this is not primarily a horsepower mod, the smoother airflow improves low-RPM responsiveness and reduces intake restriction. Over time, improved thermal management also benefits engine durability.
Q: Can I keep the stock grid heater with this intake horn?
A: The kit offers a grid heater delete segment, but it is compatible with trucks that retain the OEM grid heater. Removing it is optional depending on your climate and preference.
Q: Does this upgrade affect fuel injection or CP3 operation?
A: No. The kit is designed to work with the stock CP3 injection pump and associated high-pressure fuel lines. Proper installation ensures all sensors and injectors function normally.
Q: How does the material choice improve the intake horn?
A: Billet aluminum offers superior heat dissipation, rigidity, and resistance to thermal fatigue compared to stock stamped steel or composite parts. This reduces stress on surrounding components and prevents long-term failures.
Technical Comparison: Stock vs. SPELAB Intake Horn
| Feature | Stock Intake Horn | SPELAB Billet Intake Horn |
|---|---|---|
| Material | Stamped Steel / Composite | Billet Aluminum |
| Grid Heater Stud | Potential weak point | Deleted / Reinforced |
| Airflow Path | Restricted with center pillar | Maximized, smooth flow |
| OEM Sensor Integration | Yes | Yes, fully compatible |
| Thermal Management | Moderate | Improved heat dissipation |
| Installation | Simple but requires care | Plug-and-play with included hardware |
Conclusion
Seven years and over 74,000 miles into ownership, Sam’s 6.7 Cummins continues to perform reliably, now with a key preventive upgrade. The SPELAB intake horn provides both durability and improved airflow, making it a smart choice for any long-term Cummins owner.
“That peace of mind is priceless… knowing my engine is safe.”
Whether you’re a daily driver, a weekend warrior, or a long-haul traveler, addressing small weak points before they fail can save significant time and money down the line. For Sam, this was a preventive upgrade, but the airflow and build-quality benefits make it an all-around improvement.
John Lee
Mechanical Engineer | 10+ Years Experience
John has spent the last decade engineering and testing high-performance automotive components. Specializing in drivetrain durability and thermal management across Powerstroke, Cummins, and Duramax applications, he bridges the gap between OEM limitations and aftermarket performance. His philosophy: "Factory parts are just a starting point."
