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supercharged 5.0 true fire 98 explorer sport

hi everyone, my name is tim . i live in selkirk, manitoba, canada and as if this date that i am posting this, i am 36 years old.

i bought my sport in jan 05 from a local ford dealer. it had 111,000KM's on it. this is the second sport i have owned. it was sitting on the lot for about 8 months before i came along. i am the third owner (i was able to track down the person that traded it in, and they got it from a friend, who bought it new in 98).

i started to do a few things to it after i first got it, then i found this site, and all hell broke lose! i've never been satisfied with something the everyone else has, so i started to tinker with it even more.

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mods include

interior

installed factory tilt, cruise, overhead console, auto dimming mirror, full length console, with a message center (it didn't have these from factory).

white face with blue flames indigo gauge covers (they light up blue)
blue l.e.d. everything
white l.e.d. interior lights
Kenwood DDX392 Touch Screen Head Unit
alpine 4 channel amp (all four speakers)
boston acoustic front and rear speakers
alpine mono amp (for sub)
2 12 inch jl audio subs
rockford fosgate cap
passenger side one touch window down mod.
custom transfer case shifter
tripple a pillar gauge pod, housing autometer boost, Innovate LC-1 wideband, and oil pressure gauge
12v power inverter with 120v plug in a 2 usb plugs built into the center console

exterior

BMW E46 projectors, mounted into stock housings using clear lens
6000K HID head lights
angel eye "driving" lights, with 8000k h.i.d.'s
clear parking/corner lights
billet grill (powder coated by Turdle)
blacked out ford emblems
custom front steel 95-98 bumper, with 4 inch round tubes welded in for driving lights
shaved radio antenna
shaved roof rack
black euro tall lights
l.e.d. license plate lights
smoked out 3rd break light
lund rear tailgate spoiler/wing (formally from the truck "blackjack" owned by EF member Spas)
hand made roll pan (made from 3 1/2 rear bumpers, with 1/4 inch diamond plate on the top, and it is removable)
aluminum T/A differential griddle/cover (powder coated by Turdle)
Motegi Mr107 20' rims
goodyear wrangler hp p245/50 r20
1 1/4 wheel spacer in the rear, 3/8 in front
and most noticeable, black with blue pearl paint, and blue true fire (ground effects are black with blue pearl as well)

Suspension

2 inch lowering blocks in the rear, reverse TT in the front (2 inch as well)
Explorer Express rear sway bar
4 door leaf springs
rancho rs9000 adjustable rear shocks
03-05 sport trac spindles with drilled and slotted rotors

performance

5L swap
347 stroker
TFS twisted wedge alum heads
comp gold 1.6 rockers
comp cams CCA-35-556-8 nitro cam
heavily modified edelbrock victor jr air gap intake (which serves as a valley pan now)
eaton m122 supercharger (metco 2.70 pulley, and ASP 8 rib 7 1/4 crank pulley) with custom made mount with bell intercooler core
8 rib serpentine belt conversion using pulleys from a 7.3 powerstroke
custom made 3 1/2 inch throttle body elbow
accufab 75mm throttle body
4 inch intake pipe
PMASS MH90 90mm Universal 3000 KG/HR MAF
amsoil cone filter
F.A.S.T. 60lb injectors
edelbrock fuel rails, trick flow specialties fuel pressure regulator with summit racing fuel pressure gauge
walbro 255lph fuel pump
1/2 inch steel braided fuel pressure line from tank to rail using 8AN fittings
torque monster headers
2 1/2 duel pipes with flowpro duel in and out 2 1/2 single muffler
accel extreme 9000 ceramic 45 degree plug wires with boot protectors
4R70W w/2600 stall with J mod
tuff stuff 200a alternator
tuning made possible with sct pro-racer package, and tuned with major help from member [MENTION=102869]Dono[/MENTION] and [MENTION=81804]4pointslow[/MENTION]
flex a lite duel 12 inch electric fans
big 3 upgrade (4 gauge wires)
meziere innercooler water pump
2 froozenboost innercooler rads

Transfer case

4406 manual shift from a 97 F150
modified stock trans cross member to accept 93 mustang 5L polyurethane tans mount
double cardan rear drive shaft

because of all the "fun" i had doing the bodywork, and some other things to my truck, i have nick named it "evil dora" or if you like, just plane "evil"!
and now the thank yous

my buddy gord leiss, who let this thing sit in his garage for 3 months while i did the body work to it. he also gave me a hand with some of the prep work, and painted it for me

kevin willson for doing the true fire http://affordableairbrushing.ca/

Joe Bukoski for letting me do the 5L/4406 swap in his garage

now people from this site, weather they knew it or not, they helped

BIG THANKS to tara a.k.a. explorersport77 for pictures of her truck. wouldn't been able to build the roll pan with out them!

ExplorerSport77's X "Hotness"

jon a.k.a. Turdle for selling me some real swanky rear shackles, as well as powder coating the diff cover and sending them up to canada. as well as much needed info on v8, and 4406 swaps as well as doing the grill and showing me how its done.

don aka dono for the help with the tuning, and wideband, as well as the supercharger

andy aka ahodges for some parts, and any help i needed for all the go faster goodies

5.0 swap - w/ 4406

jad2411 for finding me a link for my hidden antenna

ryan a.k.a. MustangP51 for doing his write up on making l.e.d.'s for interior lights, and how to make projectors

P51's HID Headlight (Projector) and Fog Conversion (PICS)

and N3ELZ cardomain page for L.E.D. switch and cruise pod mods

http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-6
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-12
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-23

bob a.k.a. rwenzing for showing me speedhut's sit for the gauges

Gauges, Custom Gauges, Tachometers, Speedometers, Shift Light, Pod

Buzz4x4 for his write up on blacking out ford emblems

How to Make Your Own Custom Ford Emblems

the late aldive for his write up on one touch down passengers window mod

http://www.explorerforum.com/forums/showthread.php?t=141027&highlight=touch+passengers+window+mod

BIG COUNTRY, for his write up on how to install a auto dimming mirror

http://www.explorerforum.com/forums/showthread.php?s=&threadid=84968

BIG COUNTRY, 98formulaLS1, and Ryon40 for there write ups on how to install a message center

http://www.explorerforum.com/forums/showthread.php?t=225017&highlight=BIG+COUNTRY
http://www.explorerforum.com/forums/showthread.php?t=80670&highlight=message+center
http://www.explorerforum.com/forums/showthread.php?t=245085&highlight=Ryon40

MountaineerGreen for his 4406 swap write up and "Custom" Driveshaft for a 4406 and 4" Superlift on the Cheap " (even tho its lowered

http://www.explorerforum.com/forums/showthread.php?t=166726&highlight=awd+4x4+swap
http://www.explorerforum.com/forums/showthread.php?t=185232

Simon, aka blueka for his "pickle" thread, and help anytime i picked the phone up the phone on the 5L swap

http://www.explorerforum.com/forums/showthread.php?t=271813

Jon, aka 4pointslow for any MAJOR technical advice i have needed

http://www.explorerforum.com/forums/showthread.php?t=219092

i wish i could find who did the write up on the overhead console install, but here is the link

http://www.explorer4x4.com/overhead.htm

Russ aka NICE59FORDF100 for his help on the wiring, and what to watch out for electronically.

hopefully one day, i will be able to help people on here just as much as the people that i have mentioned above!

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plus you know you have done something right when.....

your truck (as well as corkey) wins truck of the month

http://www.explorerforum.com/forums//showthread.php?t=296023

is the feature truck on the fun hump day radio show (starts roughly around the 30 min mark)

http://explorerforum.podbean.com/2011/03/23/19-vroom-zoomboom/

and you drive 26 hours ONE WAY to the carlisle all ford nationals in june 2010 and 2011, and grab second place in the s.u.v. all category!

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then in 2014 you go back to the same show you have been to 5 years in a row (nothing by most, but its one hell of a long drive) and take first!

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Engine

That's a beautiful cross hatch there!
Looking good!
 



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i have also found a 7 1/4 crank pulley from a 94-95 mustang for sale that i will also grab (it was made at asp, and the asking price is cheaper then asp), but still nobody can answer what will happen if i dont under drive the water pump, alt, and power steering.
 






not under driving

I will give it a try,
Premature bearing failure and extra parasitic horsepower loss.
 






thing is, if i want more boost, i will need a larger crank pulley. hope its worth it.
 






Pulleys

Does anyone make bigger pulleys for the accessories on the 5.0 to slow them back down?
You could always see if any of them fail(accessory bearings) and then just replace that pulley if there is one available for it.
With superchargers there is information on maximum rpm but try to find that information on a water pump or alternator. That information is probably not available.
In a hypothetical situation where one was using a 7 inch crank pulley and a 2 inch alternator pulley, with a maximum RPM of 6500 you would have the alternator spinning at 22,750 rpm's.

The formula is Drive over driven or crank pulley divided by other pulley. That gives you the ratio and you then times your max engine RPM by that ratio to give you driven accessory ratio.

7 / 2 = 3.5
3.5 * 6500 rpm = 22,750

With a 5.8 inch crank pulley and 2 inch alternator you would have
5.8 / 2 = 2.9
2.9 * 6500 = 18,850 rpm's

Just throw in your actual pulleys sizes and maximum engine RPM to see what your accessory pulley RPM's would be.

The unanswered question is how many RPM's can the accessories handle.
As for the parasitic horse power loss, the amount of boost (and power gained from it) would out weigh that so it would still be a gain but more could be had from putting larger pulleys on the accessories.
Fuel mileage would be affected too, but who cares about that.
 






well i just pulled the trigger on the pulley. i think what i am going to do is put it all together with the smaller crank pulley to start and see what boost i get. if its too low, then i will put the bigger one on. i keep forgetting that the meth kit will bump it up a bit as well.
 






The 94/95 Mustangs used similar accessories to the Explorers, so I'd bet the rpm limits are the same. Check on the Corral forum and others to see if the larger crank pulley caused them any trouble.

There are larger pulleys to slow down the alternator, but the rest of ours may be hard to find something bigger. The cost of the 8-rib version of some pulleys like the alternator may be the same as the 6-rib, so try to figure out first if you have enough boost without slippage with the parts you've got.
 






pulleys

There are a lot of higher reving 302's and 347's out there so the accessories may just hold up to the faster pulley rpm's anyway.
 






today dono did a BIG favor for me, and drove down the the u.s./canada boarder for me and picked these up for me



thanks [MENTION=17822]Turdle[/MENTION], they look great as always!
even bigger thanks to [MENTION=102869]Dono[/MENTION] for getting them for me (he got some static at the boarder from the money hungry guards, and the more i think about even i get pissed off at it, and i wasnt even there!). jon, i think don was eying up the timing chain cover when we pulled it out of the box lol.

also in there was my crank pulley i found on corral.net for almost half the cost of what it would have been to get one made. its a 7 1/4 pulley from a 94-95 mustang made from asp. i dont even think the guy had it bolted on. so we will see how much boost i can make with this. its funny, its about a inch bigger then the pulley that was on the 347. a inch doesnt sound like much, until you compare them....



so now i wait for the block to come back from the machine shop. and now that i have these here, that wait is going to be a long wait!
 






Great new parts, and Jon does excellent work. Stay warm up there with the storm coming through.
 






Stay warm up there with the storm coming through.

warm? the snow is melting! i drove evil to dons place to pick that stuff up, and i almost didnt want to take it because i didnt want it to get splattered with road grime.
 






Were livin the life up here in south central Canada right now.
Its super warm, with next to no snow.
Every week we go, that's hopefully 1 week less of possible brutality.

I have to say, the timing cover you gave me looks awesome (Not Turdle awesome, but awesome) I picked up some of that Duplicolor high heat dark Ford blue, and will paint er up. This will save me a boatload of time on assembly before pulling my motor.

Beautiful job on the powdercoating .

Evil looked super clean tonight. Nice and sparkly.
 






Its home its home!!!!!! :bounce:......sorta
the shop called me today, and told me the short block was ready for me to come get, and now has a clean bill o' health.





so i have it at my buddy's place and the cam will be degreed in to tomorrow. i can then start putting it back together in the next few days. who knows, if i am lucky, i may be able to have it in by the end of feb, middle of march.
the machine shop owner did give me this little piece of info on how much your compression increases with boost. i am damn glad i have a meth kit for this thing as well....

 












back

Glad you got it back and everything is straightened out! Can't wait for more pics as it goes together!
 






we got the cam degreed in today. its not spot on, but its off by .5 of a degree so i dont really think i can complain about that. thanks to my buddy kurt for that. i would have been lost trying to do that.



so we brought it back to my place and unloaded it. i was going to start on it tomorrow (because its 240 am right now) but because i am having a hard time sleeping (i kinda think this thing is subconsciously stressed me out for some reason) i walked out to the gas chamber cleaned all the head bolts off, put the motor on the stand started putting the heads on.
speaking of cleaning bolts, a friendly little tip for those who are going to be putting a motor together in the near future (and you know who you are ;) ). a while back one of our old mods (SVO) put on his facebook page a picture of why you should run a tap into the treads before putting any bolts in that need to be torqued. well, i fallowed suit by doing the same thing, even though the block was tanked.



glad i did. you dont know what kinda crap may have been left behind.

with that done, the bolts lubed onward with the heads





i was going to start putting the lifters in when i realized i didnt have any oil to soak them in (and i have to figure out what way to instal them because they do have some small oil holes) i figured i would put the oil pump, shaft, and pick up in when....



someone was to lazy to walk in the house to get the bolt torque specs for the oil pump......day over!
i will have to get a new one in the morning, some oil and start again tomorrow.
 






i was going to start putting the lifters in when i realized i didnt have any oil to soak them in (and i have to figure out what way to instal them because they do have some small oil holes) i figured i would put the oil pump, shaft, and pick up in when....

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someone was to lazy to walk in the house to get the bolt torque specs for the oil pump......day over!
i will have to get a new one in the morning, some oil and start again tomorrow.



OUCH!

Looks like you are at least taking it alright. I'd probably want to cry after going through all that but I guess it is bound to happen when doing these types of things sooner or later.
 






That's ok Tim, small setback. I have a new pump in box if you need it.
 









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Supposed to have a gasket between the pickup and oil pump anyway--;)

thats what silicons for! it even works great for head gaskets to! this is a budget build :D
 






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