supercharged 5.0 true fire 98 explorer sport

CDW6212R · April 16, 2014

DIY Kenne Bell Fox air to air intercooler build list.

Check out this thread on the Corral, it's old and very good. They left the blower in place with it's location and components. But they rerouted the air charge from the blower outlet plenum, out away and to the front of the car, to an IC, and then back to the same blower outlet plenum(divided in half).

If there is about 2" of height in there under the new blower, you might be able to do something similar. The IC would then be located off to the side where there is some space, or worse case up front A2A(air to air) in front of the radiator.

Our engine bays are tighter, so there may not be space to do that at all. The IC(W2W(water to water)) needs to have some volume/size of say one cubic foot. Find the measurements of an IC from a Lightning or an 03/04 Cobra. It doesn't have to be that exact proportion, just a similar volume.

4pointslow · April 16, 2014

vroomzoomboom;3286638 not sure yet if i am going or not. it will be down to the wire andy. if i do get there said:
14 lbs of boost on my truck.
M112 off a Mustang Cobra, now we are talking!
Intercool that thing!

ford99_1979 · April 16, 2014

Suscribed... :popcorn:

ahodges · April 17, 2014

I will be utterly amazed if you can get all of that under the hood without making a scoop or a cowl induction. I had mine out for a spin last night and the air temp was 42 degrees Fahrenheit. I could tell it had more power than when it is 70 out. Intercooling is gold for more power.

CDW6212R · April 17, 2014

ahodges said:
I will be utterly amazed if you can get all of that under the hood with making a scoop or a cowl induction. I had mine out for a spin last night and the air temp was 42 degrees Fahrenheit. I could tell it had more power than when it is 70 out. Intercooling is gold for more power.

How much space is there over the driver's valve cover, with the Eaton on there now? Is it a space which could fit a box/plenum of close to a cubic foot? That looks like the only spot where a W2W intercooler might fit. Otherwise the A2A IC is the next best way, while fitting under the stock hood.

ahodges · April 17, 2014

There is basically the height of the supercharger tall, 3/4 of the length of the valve cover and width isn't really an issue. Couldn't the w2w IC be remote mounted out side the engine bay? The only issue I see is getting the intercooler under the supercharger and still having a good flowing intake. In reality we need to ditch the GT40 intakes go with an Edelbrock or something with larger ports. All of those intakes increase the deck height by another inch or so though.

ahodges · April 17, 2014

Also, where would you put the coil packs? Those hang out right there now (over the driver's side valve cover).

CDW6212R · April 17, 2014

The W2W intercooler is mounted in the airstream, so that's the tough part. That transfers the heat to the water, and then it can be taken to the heat exchanger placed up front.

I mentioned it because for Tim , it may be possible to center the M112 over the intake as desired, but pull the air charge out of it from below, divert it sideways, to the IC, and back to the intake again.

The GT40 intake is not great for boost, all of the early kits just picked that as about the only thing available back then. If possible it's a great upgrade to change to a TFS "R" lower intake. That's a great intake, but it would require the custom plenum to be made above it.

If the IC can be done, then the plenum below the blower will be fabbed or modified anyway. I'd definitely try to fit the TFS lower in there, even have it shaved on top to shorten it if needed. That's the intake I will begin with on mine for sure.

The coil packs can be placed anywhere that the plug wires will reach them, so some special lengths may be needed. Maybe place one on each side near the back.

CDW6212R · April 17, 2014

How many of the different blowers can be mounted sideways, or upside down? Do most of them require mounting them in one orientation?

It would be easier to work with a blower that has the outlet on the top, and the inlet at the back. That allows the blower to mount off to the side(left) a bit, and the outlet plenum to be right over the top. Then the outlet plenum can lead straight to the IC mounted above the intake.

I'm not trying to derail the project Tim, just point out how tough the Explorer engine bay is, and I've imagined lots of methods to mount a turbo or supercharger in there. What I just mentioned is the best method I've come up with for these trucks. Todd(tmsoko) and I brain stormed much of this about nine years ago.

Dono · April 17, 2014

When we install the M90's on our trucks, we are actually installing them upside down (At least, when we look at the supercoupe installation, that's how they are mounted from factory).
If alternative mounting can be sorted out that allows routing of the heated air thru an intercooler of some sort, this is a possibility for sure.

vroomzoomboom · April 17, 2014

at this point, (and if i do it, who knows) there is 4 1/2 inchs across, and about the same above for a cooler under the blower. i did a rough measurement last night. at this point, the first snag is the fuel pressure regulator. its kinda in the way of everything sitting lower, and it also sticks into the intake a little (andy can vouch for me on this one with the same EE kit as i have right now).
i am going to place the blower on the mock motor a little better tonight, and try and make a template for it. another problem will be is the opening between the rails is around 4 1/4. the narrowest point on the blower is around 5 1/2 (or around there) because there is a step in it, so the box will have to have a kick out. i almost want to shave it off, but i am not sure if it will weaken the case or not.

vroomzoomboom · April 19, 2014

anyone know if i can mill the bottom of the case and not have it affect anything?

if i can, i can drop the blower down about 1/2 to 3/4 inches

Dono · April 19, 2014

I don't 'think' it would affect anything. Im guessing that that lower plate was used for mounting in the factory application.
Strength? doubt it. Those rotors are already in their home, and I cant see taking that area off allowing extra flex.

Will the M112 still bolt down and have a good seal on the front and back? I don't see mounting bolts on either the outside or inside area.

Id say the only real concern is that you would never be able to sell the 'modified' M112 if you don't go thru with the build. If you do, there's no issue as you would be able to sell the whole kit to someone here down the road if you wanted out for some reason.

2000StreetRod · April 19, 2014

rotor recess

On the M90 the rotors are recessed some from the base in addition to the thickness required for strength.

I can't tell from your photos if there is a recess above the case bottom extension. Milling the extension to flush with the rest of the case would allow a larger core to fit between the case and the manifold. However, the airflow thru the core would probably be blocked from above for the larger area. There needs to be a vertical area between the bottom of the core and the bottom of the manifold for air pressure to equalize. Otherwise, flow into the cylinder intake ports will be uneven.

vroomzoomboom · April 19, 2014

not milling into the case, just taking the step out so the bottom is completely flat. after looking at some other pictures, that (if i am not wrong) would be where the stock cooler bolts to. but as i said, the stock one wont fit. if i try to open the sides of it by widening the base mount, i then surround the fuel lines, and my cause the fuel to heat up, and that is no good either. either way, i would have to get a cooler made to fit in there. if i had one around 3 inches tall, i think i would have a inch between the bottom of the cooler, and the top of the intake. thats if i go with a cooler.

CDW6212R · April 19, 2014

As mentioned there needs to be a space between the IC core and both the blower and the intake. I'd figure out what space is typically between the Lightning and Cobra parts, OEM combo's, and count those heights as part of your project. Then figure out how much that leaves for the new IC core.

The IC doesn't have to be sealed hard against the inner surrounding parts, just held firmly and with virtually no gaps around it. The pressure will be virtually equal at all points around the IC, so the air charge will go straight through it.

So figure out what potential IC core size will fit in the space available. Compare that to the core of the common blower vehicles using them, and decide if that's big enough. I would route it out to the side if it cannot be as big as the Cobra etc.

vroomzoomboom · April 21, 2014

finished the mock up

its done, so i can get all my measurements from it, and bolt patters, then send them to the place that is cutting the steel for me. i have to thank [MENTION=4156]JDraper[/MENTION] . i figured i could fine how far forward the blower should sit for the belt by hanging a string down from it like a plumb bob. well that didnt work so great. so i gave him a call, and said "jeff, seeing your a engineer, and a gearhead, here is my problem...". just as soon as i finished telling him the problem he says "ok, this is what you do....". i was like you couldnt have paused for a few seconds just to make is seem like i made you think?...no...lol. if i have done the math right, it sits a inch taller then the m90 set up, so i am still not 100% if it all tucks under a stock hood. my buddy came by last night to look at the case for me. he figures he can cut it down pretty easy, so i gutted the blower, and he will come by tomorrow and pick it up. when the plates for the box come back, i will weld them up, and start on the next fun (sarcasm) part being the intake tube.

blueka · April 21, 2014

are you sure that "wood" work???

hahahahahahaha

Si

vroomzoomboom · April 21, 2014

blueka said:
are you sure that "wood" work???

hahahahahahaha

Si

positive it "wood". if it doesnt, it will keep me from being "board"

College Student · April 22, 2014

I know this doesn't work as well but what if it doesn't make the "cut", and does that mean you are going to try and fit an inner cooler with the supercharger under the hood?

supercharged 5.0 true fire 98 explorer sport

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