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Old 11-25-2013, 09:48 AM   #76
ModMike
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Re: TKat13's Mach1 Build Log

Very nice looking build TKat13!
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Old 11-25-2013, 07:28 PM   #77
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Re: TKat13's Mach1 Build Log

great progress! keep up the good work
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2003 Azure Blue Mach 1

Stock bottom end/compression
Eaton M112
Stock upper
Stock lower
K&N intake
Built T56
Bassani mid length headers
Bassani catted x pipe
Bassani slash cut tip catback
Stock 03 Cobra IRS
18x9/10 Forgestar F14
Tuned by Chris Macduff at IMA motorsports
429hp 407 tq @ 7.5 lbs of boost
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Old 11-25-2013, 07:42 PM   #78
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by ModMike View Post
Very nice looking build TKat13!
Quote:
Originally Posted by bleedingfordblu View Post
great progress! keep up the good work
Thanks guys.

Made some progress this weekend on the motor, but first I wanted to show the k-member alignment measurements I did. I tried to type this up earlier but with the car backed out of the driveway I can explain it better.

When I installed the K-Member, I made sure it was installed as square as possible. So I did the old school plumb/bob method where I could measure front to back and cross measurements. Here is the tool:



I used painter's tape and a sharpie and made my marks on the floor. Rear is from the LCA bolts and front are at the lower control arm bolt.

I measured front to back on both sides and I was able to get both exactly the same measurement:


Then I crossed measured, this to I was able to get the exact measurement. Set and tight and remeasured and still exact.


I did this all while on my stomach, under the car with jack stands. These pictures just make it easier to visualize. Aligning the K-Member to get these measurements was actually pretty easy with a deadblow hammer. Just a few taps and done.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 11-27-2013, 03:17 PM   #79
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Re: TKat13's Mach1 Build Log

Started to piece the engine back together. Removal of the old front seal was easy with the right tool. I purchased this kit from Harbor a few months ago and have used it more than I thought I would. Absolutely love it, best 30.00 ever.


Front cover is now on:

I considered painting it but decided after installing everything on the motor you barely see it, a natural finish is fine anyway.

Valve covers on, all new gaskets. Clearly my day job is pounding keys on a keyboard as my fingers the next day was sore from forcing the plastic retainers from the rubber grommets and installing new ones the same way. All went very smoothly here.

Polished the bolt heads just a little.


Say goodbye to the old naked motor, needs a new home:
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 11-27-2013, 03:31 PM   #80
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Re: TKat13's Mach1 Build Log

I have stumbled onto 2 unexpected issues when assembling the motor.

1. knock sensors - the new motor has larger threaded knock sensor bosses. It is an M12-1.5; while the older motor uses a much smaller threaded boss, I do not know the thread yet but will soon find out. A few solutions:
  • Buy new knock sensors, but for some reason the old style is very expensive, almost $100.00 each. I have not even check if the wiring harness will work, I do not think so as the wires may be to short anyway. -wow
  • Find a threaded insert that puts will thread into the old hole and have internal threads (much smaller) and use the original bolts. Only issue here is I have not been able to find an M12-1.5 external thread, only M12-1.75.
  • Find a stud that has an M12-1.5 on one side and smaller on the other and use a nut to hold the sensor on. So far, no luck.

Solved, see post below.

2. The next issue is the coolant line from the back of the water pump to the back of the driver's head, the connection on the factory Mach block has two o-rings, and the tube just slides on. The new motor (using an older block) appears to expect a heater hose. The easy solution would be to cut the line and put a heater hose between the two. Fine, but since this is under the intake, is there a specially rated heater hose for this connection? Or will just the normal heater hose work? Parts suppliers are not very helpful with non-oem applications.

(solved) cut tube, put heater hose in-between, about 3 inches worth. Easy enough.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP

Last edited by TKat13; 12-04-2013 at 09:07 PM. Reason: How it was solved - maybe helpful to others later.
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Old 11-27-2013, 03:39 PM   #81
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Re: TKat13's Mach1 Build Log

The next decision is which Harmonic Balancer to buy? Banging my head on this one, not much of money discussion, rather which one is better for a daily driver and occasional strip use.

1. ATI Super Dampers - Model 918036.
http://www.atiracing.com/products/da...mserp.htm#Ford

2. Innovators West - Model 811.
http://www.innovatorswest.com/811-MOD-Damper.html

I hear both are great, all the research I have done say they are great. Which is better? Is there any noise with the Innovators West style? ATI is 376 while the Inn.West is 440. Both are expensive but the difference is not great enough to really matter in the scheme of the overall cost of this build.

thanks for the responses
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-04-2013, 08:14 PM   #82
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Re: TKat13's Mach1 Build Log

Wed. Update:
I decided to go with the Innovators West Harmonic balancer, should be here on Friday. I liked what I read about them and decided to fork over the additional money. The way I justified it was, with all the other money I spent, I should not cheap out on this part. I may have read to much but that is ok. Surprised that I did not get any opinions. lol

The old wiring harness was really bugging me, every time I moved it part of the old take would fall off. So, I re-taped the entire harness. My wife gave me a funny look when I flopped it on the kitchen bar and started working. I used 3M Super 88+ tape. Good stuff, high heat, great adhesive and very thick. It should be, it was 5 bucks a role and I used two.


I then had an issue with the coolant tube that goes to the back of the water pump area, the WAP block has an O-ring connection while the Teksid block had a hose type connection. Simple fix, I just had to cut the old tube, strip off the paint and put a hose between them.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-04-2013, 08:46 PM   #83
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Re: TKat13's Mach1 Build Log

Wed #2:
The next issue that came up was the knock sensors, the WAP used an M8 x 1.25 threaded boss, while the Teksid block was M12 x 1.5. I first considered new knock sensors but at $100.00 each and not really sure if the harness would properly mate up to the different sensors I decided on a much different approach.

My thought was either a stud that had different sizes on each end but this feel short as there were not any options that would work. So next on the list was a threaded insert, actually this was the first thought but I could not find a threaded insert anywhere that had outer threads of M12 x 1.5 and inner threads of M8 x 1.25. However, I was able to fine a 1/2 x 13 outer threads with M8 x 1.25 inner threads. This required me to re-tap the threads to 1/2 x 13.

Here are the threaded inserts:


To re-tap the threads was bit tricky only because I could not use the T-Handle because of the head being in the way. So, an 11/32 closed in wrench to get it started and as it got harder used a crescent wrench.


Before I started tapping the boss, I coated the threads with pneumatic oil, most of the shavings stayed on the tap.


Then I gently screwed in the threaded inserts by hand and finally tightened them down with a screwdriver
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-04-2013, 08:52 PM   #84
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Re: TKat13's Mach1 Build Log

Threaded insert for knock sensor cont...

Here is a pic of the threaded insert seated, I only re-tapped the boss to the depth of the insert so it would tighten up easily:


One side done, now repeat for the other side.


All Done as well as a shot of the coolant tube change:


The inserts were $17.00 for 10 of them, I only needed 2. Oh well, sometimes you get stuck with extras as I could not buy them locally in single quantities, but much less than buying new Knock sensors.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-08-2013, 01:53 PM   #85
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Re: TKat13's Mach1 Build Log

Man, you are really putting some attention to detail in on this. I'm impressed that you re-wrapped the whole wiring harness. Those always look so nasty. Yours looks great by the way. Keep on plugging away at it and you'll have some video up of it running soon!
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Old 12-16-2013, 02:19 PM   #86
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Re: TKat13's Mach1 Build Log

I was out of town for a week and weekend so not much has happened but I did make some progress this weekend.

Installed the passenger turbo header:


Cleaned and installed the coolant and oil adapter 'thing', you will notice the oil filter relocation adapter on the wood, the threads were too big but later found the thread reducer ring for it in the box. But it was much later so I installed the header first even though they tell you not to. Although it did restrict working room, there was still plenty of room to work with.


Installed the driver's side header, had to bend the oil dip stick tube bracket to fit around the header as it changed slightly. Took maybe 45 seconds.


Here is a front pic of the relocation installed, the in/out lines are pointing to the rear of the car to avoid any turbo piping, etc.


I used plenty of thread sealer, I hate leaks.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP

Last edited by TKat13; 12-16-2013 at 02:20 PM. Reason: wrong pic link
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Old 12-16-2013, 02:26 PM   #87
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Re: TKat13's Mach1 Build Log

Now time to installed the intake, here is a quick picture looking into the heads.

otherside:


Put in new gaskets, easiest gaskets I have ever used.


Got carried away and forgot to take a pic before I installed the upper intake, for now the upper is on just to prevent junk from falling into the lower intake as I still need to install the injectors so I will remove the upper to make the injector install easier.


Side shot


Now, I am back to waiting on parts again. Need the Balancer and injectors. All are ordered but apparently the parts I always want are the parts that are on backorder. lol
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-23-2013, 06:37 PM   #88
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Re: TKat13's Mach1 Build Log

The Innovators West Harmonic Balancer 811 came in, had to wait a few days for the ARP Flywheel bolt, but they are now finally installed.


Siemen's 80# injectors are installed with factory fuel rail.


Next on the list was to install the rear main seal, there were two, I forget what the second seal is called but it has a name. Anyway, pretty easy stuff.


Then came the flywheel, I actually had a shipment come in early!!! New ARP flex plate bolts with 242 locktite and ARP grease on the heads of the bolts. Torqued to spec.


In the past, a spacer was required when bolting up a TH400 transmission to the Mod motor, the spacer looks like the one below. But, my torque converter was made with a Ford Modmotor front, so this spacer is no longer required. Whoohoo!
Anyway, a couple of pics to show the spacer for those that may need one... btw, this one is for sale. Again, I did NOT need or use this.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-23-2013, 06:54 PM   #89
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Re: TKat13's Mach1 Build Log

Next on the list was to either buy an EGR Block-off plate or make one out of some scrap aluminum I had laying around. I decided to save the $20.00+Shipping and made my own. I just purchased a new gasket and used it as a template.





I drilled the two holes first, easier now than after cutting to size. Then grabbed my trust Dremel and starting hacking on it.


Shaped the corners with my grinder


Installed:
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-23-2013, 06:55 PM   #90
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Re: TKat13's Mach1 Build Log

Hit the 5 picture limit...
Top View.


Not a perfect fit, but overall it does the job just fine.

Trimmed my nails after seeing those pics, lol
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-24-2013, 12:16 PM   #91
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Re: TKat13's Mach1 Build Log

Had a couple of hours free last night, so I did some cleaning and painting.

Painted the coolant crossover tubes to match the valve covers.
3 coats, 5 minutes between each coat, each coat in a different direction.
Before the painted dried:


Removed the masked off areas this morning before heading into work.


Alternator Bracket:


Installed the new water pump, old one worked fine but since I was this far into the build, may as well make it all new.


Now time to prepare for installing the transmission to the motor.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-24-2013, 12:30 PM   #92
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Re: TKat13's Mach1 Build Log

Been working on the small things until I get an extra set of hands to help me stab the transmission. Tonight is the night to stab the tranny... I hope. So I prepared the plate between the trans and motor last night. HPP recommended I cut the bottom off, so I did. I placed it on the motor and grabbed a sharpie and made my lines. Hindsight, should have done this before I installed the flex plate, it would have been much easier but I still got it done.



The marks are there but barely visible, should have cleaned it. lol


left side:


Air cutoff wheel sliced it like butter, should have used this on my erg plate it was easier.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-24-2013, 05:32 PM   #93
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Re: TKat13's Mach1 Build Log

I had some time on my hands waiting for the UPS guy to deliver the 'Father-to-Daughter' gift. Wife does most of the shopping, but I always do one core gift that relates to our shared interests, it gets easier the older she gets but more expensive. lol

Anyway, with this time on my hands I have drawn up my fuel system plans. Overall, it is expensive but should get the job done. Before anyone asks, yes, I am using the stock fuel rails. I do not see the need in wasting money on fuel rails now, just to replace them when I change to a Sullivan intake down the road as they require different rails. The stockers should flow just fine, I guess we will see.

Anyway, here it is:


I may add a 2farad capacitor to the main power of the fuel pumps to handle the surge that will kick on when the extra pump kicks in. The plan is to have two pumps running at all times and when a specified boost level is reached a third pump will be enabled as a safety precaution. This signal will be controlled by the E-Boost2 controller. The other signal will be ignition 'on'.

Also, I should add that the '(<letter>)' in the drawing is a reference to my Excel spreadsheet for brand, part number, cost etc. Helps with my planning. I may be a bit OCD.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP

Last edited by TKat13; 12-24-2013 at 05:34 PM. Reason: To explain the letters in the drawing
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Old 12-25-2013, 12:05 AM   #94
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Re: TKat13's Mach1 Build Log

I was able to meet my goal today and install the transmission, buddy came over to lend a helping hand. The other night I filled the torque converter with a quart of transmission fluid. Took a couple of hours with a slight tilt. PITA for sure.

Added some grease in the crank end.


Stood the transmission on its end, made installing the converter easy. Three click and it was installed, really easy to do.


Trans on a transmission jack and just slid it on the block, bolted down... all good. Very easy job, I was surprised as this is my first Auto install.


The space between the flex plate and the torque converter is more than the specification allowed so I need to get some spacers. Easy enough but everything is closed for the holidays. I hope to drop in the car on the 26th. Fingers crossed!!!

Everyone, have a Great Christmas and enjoy your families! The Mach will be on hold tomorrow.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-27-2013, 12:07 PM   #95
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Re: TKat13's Mach1 Build Log

With the help of a buddy, we dropped the motor&trans in yesterday. I ended up having to remove the passenger side header as it was a bit wide. Now I get to have fun installing it from below.


Need to fix all the wiring and installation of the nitrous, had to move it all out of the way. The heater hoses, what a pain again. I am sure there is a trick, but this being my first attempt at installing from the top I guess I got through it. Only took about an hour, but I was being a bit cautious.


After dropping in the motor, I installed the alt. and brackets. But first a raised the car back in the sky, so much easier to work on when lifted up high, better on my lower back and easy to get around underneath.


Next on the list is the passenger side header, AC, Power steering, Trans bracket, driveshaft. If I get all this done this weekend then that is a success. Hopefully still leaves time for the family.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-30-2013, 02:16 PM   #96
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Re: TKat13's Mach1 Build Log

Biggest item on the list that was completed was the transmission support. I started with the stock Mach support, removed the rubber trans mount by drilling out the rivets. At this point, I jacked the transmission into place and marked on the support bracket where I planned on cutting. Then it was a matter of playing with the cut-off wheel.







At this point I measured the length needed for the main support, made the cut, then drilled two holes for the Prothane trans mount. The holes were for 7/16" bolts and were 1.5" center to center.

Then mounted the bracket, placed the plate on the transmission and tack welted into place, then removed and started more fabrication. You can see the tack weld marks.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-30-2013, 02:21 PM   #97
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Re: TKat13's Mach1 Build Log

At this point I just started to box in the support bracket for strength, I may have gone overboard but that is ok.


I know, not very pretty.



Time to clean it up.
Pulled out the trusty grinder and got to work.


My vision starts to appear..


I know it is not perfect, but it is functional.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-30-2013, 02:25 PM   #98
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Re: TKat13's Mach1 Build Log

Finally prepped it for paint and gave it a coat.




Installed on the car, fit perfectly, not even a nudge needed it just slid right into place.


I was also able to reinstall the passenger exhaust header. Was a bit lazy after the trans mount so maybe tonight I can get a couple of other items knocked off my list so I can start the turbo piping.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
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Old 12-31-2013, 01:54 AM   #99
TKat13
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Re: TKat13's Mach1 Build Log

1. Tonight I was able to install the AC and all associated wire harnesses.

2. I also installed the hydraulic pump and then I say the bad, the pressure side of the pump hose is leaking, I am sure I damaged it at some point during the motor install. Chalk one up for a big oops as it turns out. This is because I cannot seem to find one anywhere!!! I guess they are not supposed to break/leak...

I guess I will have to make one out of Aeroquip -6AN Startlite hose and those expensive fittings. Really annoying. I will post up the parts used to create this hose setup, still very annoyed.

It is now finally time to start test fitting the Turbo kit, plan to start this on Friday after work.
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Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 12-31-2013, 11:39 AM   #100
lcaptmorg
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Re: TKat13's Mach1 Build Log

Awesome work. Thanks a ton a head of time for all the work you have put in posting up pics. Im sure it is a ton of help to many of us.
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