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Completed Project My 98 super charged EX

Use this prefix for completed projects that are not "How to" articles or threads asking for help.
1998 Explorer 4.0 SOHC
Bought it with a melted alternator/wiring harness from a junkyard for $1,000
Fixed it, drove it for two weeks, then I boosted it.
Started with an M90 supercharger kit from www.Bansheesuperchargerkit.com
Upgraded to an M112 Lightning supercharger that was a prototype kit.
Next was the M122 off a 2012 GT500
I have reached 20 lbs of boost (with ARP head studs) and a 12.83 in a quarter mile.

Pictures
1. How it looked when I brought it home.
2.The M90 supercharger installed
3.The GT500 supercharger installed
4.How it looks now
5.Wheelie
green ex.jpg
DSC02710.JPG
5.JPG
Lowered Rear.jpg
Exploder wheelie.jpg
 



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Good work, now you can work out the new A/F tune and see the gains.
 



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Exhaust

I agree, time to get that A/F tuned!
Cant wait to get to the track! Hoping to on Tuesday next week.

Tomorrow is back pressure test time if it doesn't rain.
 






Back Pressure

I just got done testing back pressure at WOT with the new exhaust pipes.
Still have a little over 10 psi back pressure. WTF?
Was not expecting that.

The cats look to be a little smaller in total size than the original ones, maybe that is an issue. One reason cats are so big is so they can flow the same as the pipes, but with the monolith being in there.

I may have some cut outs / dumps welded in right before the muffler, just cheap ones with block off plates. Then I can remove the plates at the track and check the back pressure without the muffler and tail pipe. If it is still 10 psi then the cats are the restriction, if it drops then it is the muffler and tail pipe configuration.

Still going to the track on Tuesday with this set up if the weather permits.
 






Rear O2 sensors

Now that I think of it, I can just remove a rear O2 sensor and test back pressure there, if it is 10 psi then the muffler and tailpipe are the issue.
If it is lower then the cats are still restrictive.
 












Flow rating

I have no idea, still have no idea what brand they were. I will have to check with the exhaust shop when I have time.

Tomorrow I plan to do some more back pressure testing, going to do the right side since I tested the left side already, and then try the rear O2 holes on both sides. I will post the results.
 






Cats

I just looked at my receipt and found the cat part numbers.
They are Magnaflow 51176 according to the receipt.
Cant wait to see if there is 10 psi after the cats and before the muffler tomorrow.
 






Those cats are not too expensive, I would have guessed that they would use some types that run $200-$300 apiece, given their appearance and the request for a stock look.
 






I just looked at my receipt and found the cat part numbers.
They are Magnaflow 51176 according to the receipt.
Cant wait to see if there is 10 psi after the cats and before the muffler tomorrow.


I'm fairly sure what you have is a big restriction of the rear exhaust.

Think of the smallest point, the bottleneck point. What is the total size/area/flow of any location along the exhaust.

What are the typical areas of a common fast car of say 12 seconds? What are the total area sizes at the tail pipe tips, the total muffler inlet and outlet areas?

It's a given that 14.7 lbs of boost produces about double the airflow, so for a 4.0 engine that means about 8.0 liters of airflow, at an rpm of 6000. What kind of pipe sizing should that need? What tail pipe area, total, should be needed, and the muffler inlet/outlet area total etc.

The stock Explorers have a single 2 1/4" tail pipe, and one muffler. Mustangs V8's have always had at least twice that in just stock form. So the stock Explorer is 1/2 of what a stock Mustang uses, and that's too small. Mustangs typically go to dual 2.5", but 3" is what most truly fast cars have, at the least.

So for a 12 second vehicle, I suggest shooting for that 3" dual total area. Try to achieve that at the tail pipe tips, at the muffler inlets(total area), and all bottlenecks.

That means that two mufflers will outflow one, by double, given the same model mufflers. There is plenty of room for two mufflers, only the tail pipes are hard to work out. Dump one there at the rearend if needed.

From looking under the back many times at where the tailpipe goes over the rear, and the left side, I think I'm going to be able to make one fit on the left. Whether there's room for a 3" pipe is what I'm not sure of. The 3" tail pipes common to get for the Explorer means that the right side is no problem. But whether there is room to turn one left along the rear is the tough question. Most people have taken it into the spare area. I want to keep a spare there.
 






exhaust

I am thinking you are correct with the muffler and tail pipe being to small.
I guess we will see with the results of the back pressure test I do after the cats.
I have already been looking at different options if it is the muffler and tail pipe.
Dumped the spare for weight reduction so I have more room back there. I saw some pictures of others dual exhaust under explorers so I know it is possible.

What are your thoughts on this muffler, it is said to be good for heavy duty gas and diesel trucks?

http://www.flowmastermufflers.com/?...year=&model=&submodel=&engine=&category=0&kw=
 






That's not a cheap one is it?

You should try to go with a muffler type that you like a lot, for the sound and loudness. There's a ton of choices and examples here on the forum. Some you know are a little quieter, and most are straight through types and louder. I think the Super Turbo type are among the quieter ones, some of the chambered kind too. I'd try trust what others say about how loud one is.


But whatever you do like, choose two and make them fit. Not all can fit well as pairs, given the thickness of the mufflers. I think the space under the trucks is about 8-10" high, depending on how low you are willing to bring them down. There's plenty of length and width space. My friend here put two Flowmasters under his 97 Explorer in 2004, angled a lot, and they barely showed under the truck.

Just remember that adding a muffler alone(like the one you have), that will halve the restriction. Everyone keeps sticking one muffler under the truck and thinking it flows as much as two mufflers. One muffler flows half as much as two mufflers.
 






Go to the exhaust thread and take a look at my setup
 






Its page 27 of the 5.0 exhaust thread in the modified second gen stickies, I know I'm running the V8 but its in a sport and honestly it would all probably fit a sohc with little work to the first little bit of the down pipes /cats, but its the muffler and tails that would apply to what you have now
 






...

Just remember that adding a muffler alone(like the one you have), that will halve the restriction. Everyone keeps sticking one muffler under the truck and thinking it flows as much as two mufflers. One muffler flows half as much as two mufflers.



That's the problem with what people are doing. Everyone keeps suggesting you get as much airflow with one muffler as with two. Nobody is installing two mufflers under these trucks, and you don't see many fast vehicles that only have one muffler.

If the point is stock or mild, nothing special except what it sounds like, fine, stick one muffler under it.

If the goal really is performance(fast like at the track fast), then one muffler is a very bad idea. Double your airflow by installing another muffler, and the tailpipe.
 






So an x pipe is no good ? Cause that's what my muffler is and that's long proven to work in mustangs
 






So an x pipe is no good ? Cause that's what my muffler is and that's long proven to work in mustangs

That Mustang example is of an "X" pipe cross over, ahead of two mufflers. The V8 Mustangs all have two mufflers and tail pipes, and that is bone stock, which is not big enough for real high performance.

So that 2.25" dual exhaust system of a Mustang should be seen as a low flow system, and yet the 302 Explorer has half of that airflow potential from the single muffler back. Open up the exhaust from the middle on, double the mufflers and tail pipes, and all you have achieved is to reach the low flow system of a bone stock V8 Mustang. That is how pitiful the exhaust is on all Explorers, it's basically half of what a stock Mustang comes with.

Truly fast cars have a huge exhaust, or none, and an "X" cross over is another restriction(it forces all of the air through one small location(bottleneck)).

It's all thermodynamics, and many people can follow it that way. Think of the cross section of the exhaust at each unique point along the way, front to back. Imagine looking from the back, at the cross section of the exhaust as you would cut it in pieces.

Think of the air mass having to flow through each cross section, think of the single section in places that the entire exhaust has to get through. It's the total area of each cross section that matters. Having two mufflers provides twice the total area of the cross section that the exhaust flows through. Two tail pipes does the same thing, as does two headers, cat pipes etc.

It's about reducing the bottlenecks, and having just one muffler, that's a big bottleneck. Regards,
 






Exhaust

Thanks for the input guys! I really appreciate all the different ideas and concepts.

I just checked the back pressure after the D/S cat but before the muffler.
It is about 8-9 lbs. That proves that there is restriction in the muffler and tail pipe design.

Logically it makes sense that (2) 2.5 inch inlets would flow more than one 3 inch outlet. I am thinking the best way might be 2 mufflers with 2.5 inch inlets (since that is what I have now)and (2) 3 inch outlets/tailpipes. But how to make it fit, that is the question.

As for sound, quieter would be more desirable to me, but I don't want to sacrifice flow/quicker 1/4 mile times.
 






Flowmasters

Looks like I will have to get mufflers with 3 inch inlets and outlets, I don't see any 2.5 ins with 3 inch outs.
The muffler shop should be able to go from my 2.5 inch pipes to the 3 inch inlets. Hope there is room for two 3 inch tailpipes.
 






My 2.5 pipes are tight but it should work , magnaflow had some nice glass pack sized mufflers with staggered sized in/out , summit has a good selection and when I did my brother in laws f-150 I got him a flowmaster with 2.5 in 3 out from summit ,it was the hush series but it made his 4.6 sound like a big block with the single 3" tailpipe
 



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Looks like I will have to get mufflers with 3 inch inlets and outlets, I don't see any 2.5 ins with 3 inch outs.
The muffler shop should be able to go from my 2.5 inch pipes to the 3 inch inlets. Hope there is room for two 3 inch tailpipes.

Do what you can to open it up. You are producing a lot more airflow than normal, so it needs a lot more exhaust.

I've heard or tried a decent number of mufflers too, and it's still hard to pick the next ones. I will get a shot at the Vortex things I got 2-3 years ago. These are almost flat top and bottom, 4" thick, so they can be stacked or even welded together. I hope not to end up wanting it quieter, and looking at some kind of resonator(another restriction) later.
 






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