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1996 5.0L mods

tool_man

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Year, Model & Trim Level
1996 Explorer 5.0L
I'm interested in getting 300 HP at the crankshaft at about 5500 RPM in a normally aspirated set-up with no NO2. Has anyone had any dyno experience doing something like this to say what kind of parts it takes?
 



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Just out of curiosity... What is your level of mechanical skill and background?
 






Youre ex has the gt40 intake and heads correct, if so i would personally take it out redo all the seals and gaskets check crank bearings and replace them if needed basically refresh the bottom end, Then i would put A msd ignition, cam, headers, and a programmer, as well as getting the heads ported and polished. Then i would also get a bigger throttle body, and a programmer. That setup should be near 300 or more hp at the wheels..
 












My skills and tools are appropriate for carburated engines but the electronics don't scare me. The '96 has the GT40 heads and the tall intake, both of which I think I'll use to keep the cost down. I suppose the cam will change and I'll add headers and a programmer and a 90mm 19lb/hr TB.

I was hoping I could take advantage of someone else's dyno experience to minimize some the experimenting and associated costs.
 






I do know that on a 347 shooting for the 350 -400 hp range, a 70mm throttle body actually works better than a 75mm. I don;t think you need to use a 90mm. I would try to use a 90mm lightning maf for simplicity, since you do not need blow through metering. A good tuner MUST be included in the plan. Are you going to dyno tune, or do you want to do remote tuning thru datalogging?


The stock upper "should" be good for 350 hp with the right supporting mods, but I doubt you'll find headers which will flow well enough. This is why you will need the nitrous. I'd focus on longer exhaust duration and better exhaust flow to get the heat out.
 






Oops. Please excuse my DA. I meant 90mm "MAF" not "TB". I'm OK with welding and fabrication. If I have to I'll make my own headers. What do you know about "Tweecer" tuners?
 






If I have to I'll make my own headers.

So many people have talked about creating their own on this site. I don't think any have actually done it. Find some Torque Monster Headers and move on. ;)
 






i dont know what the big deal about makeing headers is, if you got a pipe bender or buy the proper angles and can weld, you can make them, but just getting torque monster's would be so much easyer
 






i dont know what the big deal about makeing headers is, if you got a pipe bender or buy the proper angles and can weld, you can make them, but just getting torque monster's would be so much easyer

Please make a set and come back to tell us how big a deal it is. :thumbsup:
 






I have made a two pairs of turbo manafolds... Not a big deal if you have a cheep mandrel bender and a good tig welder.


Don't get me wrong it is a time consuming process and can be very frustrating. But if you have all the stuff to make them do it.
 






Welding headers from a pre-bent kit for other cars is already a friggen pain... I don't want to get in and measure all the angles and sizes to make one inside this engine bay... I mean, making a log isn't REAL tough, but anyone who says making a set of headers is easy has obviously never put a set of headers together before.
 






I never said they were easy to make there just not a huge deal to make them.
 






I never said they were easy to make there just not a huge deal to make them.

DO it then. Prove your point. Typing will not get us better flow--start bending and welding.
 






Ok, here you go.

Here's an exhaust flange for a 302 with ports that would be MORE than big enough for 350 HP while still giving you room to slip primaries in and weld them on.
http://www.jegs.com/i/Kooks+Custom+Headers/579/7009/10002/-1

Here's some pipe with bends
http://www.jegs.com/p/Hooker-Header...ax-Exhaust-Tube-Mandrel-Bends/744799/10002/-1

Here's collectors
http://www.jegs.com/p/Hooker-Headers/Hooker-Headers-Formed-Collectors/763744/10002/-1

and here's a ball and socket flange
http://www.jegs.com/p/Flowmaster/Flowmaster-Header-Collector-Ball-Socket-Flange-Kit/752165/10002/-1

Everything you need to make a set of headers for your non-egr 302.
 


















If headers are the deal-breaker in the project then that's good to know. I have a brother-in-law who, when the time actually comes, has everything needed including a machine shop, pipe bender, and a TIG welder. He's a welder by trade and makes a part-time living fixing super-modified chassis that have been wrecked.

If you were going to write the spec for the headers, what would it be?
 






It's a friggen 302. If you knew what you were doing, you wouldn't have to ask this question, or you would have already read on the mustang boards and found a dozen other bottle fed 302s. That's why I asked you what your background was, your question was dubious to begin with. I have a brother who is a welder, a damn good one at that, but I still don't poop headers. Heck, my other brother is a computer programmer, but you don't see skynet in my living room do you? I was a mechanic for years, but it is still JUST AS MUCH work for me to change my oil, and I am a mathematician now, but 1+1 still equals 2.

Heck, every guy who comes onto this site and talks about building a set of headers has a brother/uncle/cousin/dad/neighbor/roommate's mother's second cousin's nephew's friend's baby daddy that is a welder. See a trend here? If you are going to make a set, don't tell us why you can do it, just go do it.
 



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heck, every guy who comes onto this site and talks about building a set of headers has a brother/uncle/cousin/dad/neighbor/roommate's mother's second cousin's nephew's friend's baby daddy that is a welder. See a trend here? If you are going to make a set, don't tell us why you can do it, just go do it.

yep i have seen it 1000 times. I my self have tryed. Its not easy. Very tight and not fun
 






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