New Project "R" thread

[birdman941]

FO is right about the Boss 290. :ORANGE:
Those Au. Ford are pretty potent.

Made more progress today on the upper.
STOCK Mach 1 Air inlet hose and TB are temporarily hooked up.
Will try and post pics later, too late now.
Still have to do:
IAC configuration
Throttle cable/cruise bracket
EGR configuration (using a stock Mach/99-01 Cobra pipe)
Will be working on it all day tomorrow.

Originally Posted by Marks04DSG

You know the show on cable "V8 SUpercars" Think I've seen Boss 290 insignias on some of those Austrailian Fords or Falcon which always seem to beat the Holdens which are their GM GTOs if I am not mistaken??

Steve: lotta progress on that manifold, if that was me I'd still be reuppin on the dew

Plenty of Mt. Dew here!
That and coffee tonight!
Long day.

[birdman941]

Air inlet TB shot with prototype upper intake installed............
(still working on it today).............

[birdman941]

I picked up a stock 99 Gt hood today from my buddy Gary
that owns a body shop in town.(Scratch and Dent shop in Fort Myers)
They did all the body work on my Mach 1 last year.
The hood was off a wreck, and the front the hood is a little crunched.
But, with a little work, a Stock GT hood looks as if it will clear the
Upper intake of the swap "kit".
A hole will have to be cut in the low portion of the phony "scoop" area,
but I think the factory scoop will cover it.
I will have pics later today.
Think of it.
A normal, every day looking 99-04 Mustang GT with a 5.4 32V under the hood.
Quiet, smooth, with 400 plus Boss 330 horsepower under the hood.
And no one will be able to tell from the outside.............................
Sleeeeeper.................
Pics later today.

[birdman941]

Here are some pics.
I need to get a GT hood scoop to make sure,
but it looks like the engine height development worked out OK.
I think a GT phony hood scoop will cover it all!
It will most definitely fit under a Mach 1 hood!

Side view with the Mustang GT hood.



Front View with the GT hood.



Top view.
There is extra "hole" clearance,
which I need to develop the throttle and cruise cable bracket.



Back to work for me!
Mt. Dew is a waiting!

[98StangRidah]

that's a nice wing on the roof there

[birdman941]

Originally Posted by 98StangRidah

that's a nice wing on the roof there

Yeah, I was so psyched that the motor fit under a stock hood,
I didn't move it.
Update:
Got the throttle linkage bracket done!
Yee Hah!!

[SIrRicCuS]

Originally Posted by birdman941

Yeah, I was so psyched that the motor fit under a stock hood,
I didn't move it.
Update:
Got the throttle linkage bracket done!
Yee Hah!!

Will you sell me your car when you're done? Hahahahaha! Just kidding, birdman! It's coming out awesome though! Keep up the excellent coverage!

[birdman941]

Originally Posted by SIrRicCuS

Will you sell me your car when you're done? Hahahahaha! Just kidding, birdman! It's coming out awesome though! Keep up the excellent coverage!

Sure, when it's done!
Cruise bracket and throttle return spring bracket (using STOCK Mach spring and bracket):
Done.
Throttle works perfectly.
This weekend: EGR and IAC

[Marks04DSG]

Makin some good progress man, glad to see it workin out ..

[birdman941]

Thanks.
I am still amazed that huge motor fits under a stock hood.
GF says it's because I am "Monkish" with every detail.
So far, 99% Genuine Ford parts too.

[birdman941]

Worked on the upper intake all day today.
IAC is finished. (whew!)
Have to have that or it won't idle.
Also, the 4 mounting points down the center of the upper intake are done.
EGR should be done in the next couple of days.
Maybe tomorrow but I doubt it.
It's really shaping up.
So far, only wire 1 needs to be extended, but no other wiring issues so far.
Factory Mach or 99-01 Cobra wiring harness goes on with no changes.
Vacuum harness seems like it will follow suit.
Only 1 radiator hose mod (very slight 1" trim, new part not needed).
Stock Heater hoses, throttle and cruise backets and cables go right on.
Easy plug access. (as easy as a 4.6 32V)
All in all, a long but successful day.

[LNCHBOX]

As long as I've been following this, I never expressed how awesome this is. This is one of the coolest projects I've followed, and I can't wait to see the results. Keep up the excellent work.

[birdman941]

Thanks.
Today was a successful day in the garage.
The IAC had me worried, but it's handled.
Edit:
Pics in a mimute.

[Linumup]

Originally Posted by birdman941

Thanks.
Today was a successful day in the garage.
The IAC had me worried, but it's handled.

It just amazes me how the common man can can make great things . Why is it Corporate America cant . Awesome job . Im still watching . Be talking to you soon as soon as you finish .

[birdman941]

Here's a pic of the IAC and the DPFE.
The location is dictated by the size of the engine, the shape of the upper,
and the configuration of the fuel charge harness.
The IAC is a mind bender to make it work.
There are 2 "holes in the IAC /motor/valve.
One specific one must be for direct engine vacuum.
One must be for atmospheric air from the TB before the blade entry.
Get them backwards and the car will not idle at all.
I got it done all internally inside the upper intake, (no external hoses like 2000 GT)
without blocking airflow through the TB nor after it.
I have been thinking about it for a month or so.
The simplest solution won. (it was a no brainer)
I already spoke to Roy (who is doing the metal fabricating for this adventure)this afternoon and explained what I did.
He says he can do it, and I believe him.
Think about this for a second.
All I gave Roy was an Aussie upper intake to work from.
What I got back was a prototype that not only fit, but fit well,
and is so workable, it will need very few changes!
Hats off to Roy! :ORANGE:

IAC motor location:


Updated lid:

[ITLRUN]

That intake is going to be an awesome piece.

[birdman941]

Thanks.
Once this is done, maybe some more interesting developments.
Maybe...................

[Roy]

Lookin good man! I'll probably make an aluminum throttle cable bracket instead of using the stock one. It can bolt or weld to the lid.

[Marks04DSG]

Man you guys are making progress, what is that mockup material, masonite? Good thinkin.

[birdman941]

Sounds good.
I would like to get the cable bracket height down a bit,
but the geometry and TB to bracket distance has to be correct.
Roy is the man!

[birdman941]

Originally Posted by Marks04DSG

Man you guys are making progress, what is that mockup material, masonite? Good thinkin.

It's like pegboard without the holes.
It was Roy's idea completely.
Hot glue stick gun for bonding.
The next prototype will be aluminum cut on a waterjet and welded.
I have an interesting EGR issue I have to investigate tomorrow.
This may actually pass "sniffer' emission testing for areas that require it.
Trying..................

[xxxxMach1]

I wish I could do something this complex! Hats off to you man, you're gonna have yourself a nice 1-off when its done.

[birdman941]

Thanks.
Hopefully, others may want to take the "extra cubes" plunge.
I am doing it this way so if others want to do it,
the legwork is already done.
The goal is to utilize as many Ford parts as possible,
and being able to do the swap without even 1 trip to the parts store.

Alternator/coolant crossover bracket prototype almost done.
EGR issue "fix" in the works.
So far a total of 3 non-Ford parts in the entire swap deal.
Still working in the garage today.
Mt. Dew keeping me refreshed.

[SIrRicCuS]

Originally Posted by birdman941

Thanks.
Hopefully, others may want to take the "extra cubes" plunge.
I am doing it this way so if others want to do it,
the legwork is already done.
The goal is to utilize as many Ford parts as possible,
and being able to do the swap without even 1 trip to the parts store.

Alternator/coolant crossover bracket prototype almost done.
EGR issue "fix" in the works.
So far a total of 3 non-Ford parts in the entire swap deal.
Still working in the garage today.
Mt. Dew keeping me refreshed.

Lol! I haven't had Mt. Dew for years!!!!!!!! Probably a decade! Hahahaha!

[birdman941]

Alternator/coolant crossover support bracket partially done. (prototype)
Not pretty, but functional.
Final will likely be aluminum.