CHIEF Is Almost a 302!!!!!! 91 XLT SAS In the process of 302 and T-5 Swap!!

[Chief34]

I really need to rotate my t-case up a little bit to get better clearence for my front driveshaft between the tranny crossmember. The engine is already tilted a little and the mounts are welded. So the only thing I can thing of is trying to use a different bellhousing that doesen't angle the tranny towards the driver. Does anyone know which year bellhousing is NOT angled toward the driver and is sticking more straight up and down??? Anyone?

Second, I got my intake adapter and 94/95 throttle body in the mial. Good news was it did clear my A/C box for the most part. Bad news is there is still interference with the A/C box and throttle cable linkage which is on the side of the throttle body. I am going to have to do something about that now. Then I had to order an adapter harness to use the "tps" from the 94/95 throttle body with the earlier harness system. That was ok, it was only about $14.00. More bad news was the Egr valve set up is different. I have to figure that out now as well.

Third, I got my altenator in and that all went as planned thank God. Looks good and mounts perfect with the right harness connection.

Next, I am going to haver to make a custom pulley because I switched the water pump and timing cover to the shorter style. The dont make any pulley that is designed to let you use the 94/95 style short water pump and timing cover with the earlier style engine. I dont think it will be too hard if I just modify my stock pulley. I'll make sure to include each fix for these damn problems as I figure them out. Until then anyone with suggestions, please feel free to share them with me. Thank-you,
Tim

 

[Joe Dietz]

Consider flipping your intake 180 degrees

Tim,

The way I solved the AC dryer box interference was to flip the upper intake manifold 180 degrees. Yep you can do that...I did use a straight throttle body and intake from '89-'93. Curved '94-'95 may give you more trouble...You can check out the pics of my install on my website.

Joe

 

[prerunnersvo]

Hey man, I just wanted to say you're doing an awesome job. I put an EFI 5.0 in a ranger a few years ago & mine was no where as nice as yours. got to tip my hat to your attention to detail!!

 

[NOTAJP]

Tim,
My father-in-law just got some custom pulleys for his Mustang 5.0 in his Bronco II. I'll ask him where he got them and post for you soon.

 

[Chief34]

Joe,
Thanks, I have already read about your project. You did a good job. I dont want to flip the intake however and I am kind of already committed because I fliped my battery over to the driver side as well. Thank-you for suggestions though. Every bit helps.

Prerunnersvo,
Thank-you very much. I try hard to get everything done the trick way. It's just my nature. I am kind of a perfectionist. I know it will all be worth it when it's done.

NOTAJP,
I would really appreciate that. If it doesent pan out, I have an idea of how to modify my stock pulley. Basically The pulley needs to mount flush with one edge of the pulley instead of bieng offset forward or rearward. I am thinking of taking the stock pulley and torching out the center, so that it is a "doughnut" shape with just the smooth outer ring left. Then, Cutting out a round piece of steel maybe 1/8" thick and laying it, recessed, on one side of the pulley and welding it in. The only concern I have with this is warping the pulley from heat. I am probably going to rig up a little jig to hold it flat. I am going to work onthis today. I will get pics. Definately let me know if you find out about pulleys though. Thanks again.

Lastly, I am going right now to get a plastic welder from harbor freight. I am going to just modify and customize my box to accomadate the intake. I will get good pics for everyone.

Keep suggestions coming!
Tim

 

[Nicaraguense]

WOW

I wish I had that kind of time and money I could pour into my rig. (pretty much stock... Oh wait, I changed that crude oil out to Amsoil Synthetic, and added PFC (Performance Friction Carbon Metalic Brakes). JUST NO MONEY WHEN YOU ARE GOING TO SCHOOL AND ENGAGED TO A LITTLE NICARAGUAN GIRL.

 

[Chief34]

Hello Again,

I fixed my ac box clearence. I just cut out a tiny bit more to clear my throttle cable. Good thing it clears now because it is cut out as completley far back as possible.

As for my pulley..... Notajp.... Have you heard anything from father-in-law?? I started working on my stock one just incase and here is a pic of what I have done. This pic shows the pulley and where it needs to mount. You can see that the mounting point on the water pump is fluch with the back side of the pulley....

 

[Chief34]

So I torched out the center.....

 

[Chief34]

I smoothed it up and this is what is left....

 

[Chief34]

So now I need to get some 1/8th inch steel and make a flush side for the pulley. It is still true to shape. The next big thing will be welding the new piece in without warping or destroying the pulley. I think I can get it though. Then i'll just take it to a machine shop and get it balanced. i'll keep you posted on how it goes...

Next Was my Ron Davis Custom Radiator........!!!!!!

 

[Chief34]

It is a Double pass Design which is why the inlet and outlet are on the same side. It also was made for me without a filler neck. Instead it has a 1/4 NPT thread to run to a header tank. You can see it in the upper right or passenger side. This radiator is 28" wide and 19" Tall
2 row 1" tubes with 18 fins per square inch. 3" tank thickness. yes. It is bad to the bone! Anyway here is another shot from the side. It is fully tig welded.

 

[Chief34]

Here is a shot of it in the truck, But what you cant see is I already cut the lower RAD support out and I still need more room!!

 

[Chief34]

Solution::::::

Before .......

 

[Chief34]

SOLUTION::::


AFTER.....

 

[Chief34]

Yes. It is gone. I am going to just make a new front support. Strong yet it will have clearance. I had plenty of clearence side to side. I just needed more hight. Which obviously I have now

 

[NOTAJP]

Pulley Info

Here's the info that Kerry got for me. I'm not sure if they machined the pulleys for him or ordered them for the custom application. He has a racing water pump. All his pulleys are polished alloy so they look nice too.

Just tell them exactly what you have and what you need and they'll get it done.

Rapp Racing
Central Point, OR
(541) 664-2235

Good luck!

 

[92eddie4x4]

I am at a loss of words.

 

[Chief34]

93Eddie,
Thank-you

Here is the latest. I have been woking on some things. First I got my 94-95 Style intake adapter in. I am now using the 94-95 style throttle body as well. This did pose a couple problems however....
1) The Throttle position sensor is different.
Solution: Very easy I ordered an adapter harness from Ford Racing that plugs into the 94-95 style TB and then into my early style harness. That fixed that for a mere $13.00 Also, Still looks stock.

2) The other problem is that the 94-95 style intake uses a different style egr. Instead of bringing exhaust gases from a passage in the heads up to the
"egr spacer" through a passage in the intake, It actually brings exhaust gases straight from the header up to the back of the egr valve itself.
Solution: I am going to use the 94-95 style Egr valve which still plugs into the computer harness the same way with the same sensor. Then I am going to run the egr line down and tie it into the exhaust gas lines on the passenger side of the engine. I will get pics of this when it is done. The TB adapter actually blocks off the original exhaust passage ways in the intake when it is bolted on which seals that off and fixes that.

Here is a pic of the new TB adapter on the engine and how it misses the A/C Box. I also made a bracket to hold the Throttle cable which is now functional....

 

[Chief34]

The next thing That I have been working on is the Radiator support which is finished... Here is what it turned out like. Let me also add that it is super strong. You can stand on any part of it and bounce up and down and it is solid....

 

[Chief34]

Here is another look at it from the side a lil... I am going to use Stainless steel hood latches from Ford racing to hold down the hood. You know that "Pin" style you see on fiberglass hoods.... Notice there is not a hood latch anymore.... Also, The Support goes down between the Frame rails a little bit.