STS Turbo 98' 4.0 SOHC Explorer Sport pics and tune....

[Silver X]

So once this is tuned and whatever bugs worked out, are they going to offer a kit for Explorers? Or is this just a one-off?

 

[Katmandu]

Great Project guys!

Can someone elaborate on the different fuel systems from the quote below please ??

Focus SVT fuel pump CONSIDER YOURSELVES WARNED, THEY ARE DESIGNED TO BE IN A PWM SYSTEM NOT A CONTINUOUS SYSTEM

 

[CDW6212R]

The 99+ Fords use a pulsed type of fuel pump, because there is no return line(returnless).

The older fuel injection Ford's are return fuel systems, with a complete loop to constantly pump fuel to and from the fuel tank. Regards,

 

[2manytoyz]

that is a sick idea! Hopefully nobody gets under your X and saws off the turbo
im sure you keep a close eye!! good luck with that sleeper!!

 

[rocket 5979]

that is a sick idea! Hopefully nobody gets under your X and saws off the turbo
im sure you keep a close eye!! good luck with that sleeper!!

If it is mounted pretty sturdily then it will be pretty hard to saw off and take.

 

[Doug904]

The 99+ Fords use a pulsed type of fuel pump, because there is no return line(returnless).

The older fuel injection Ford's are return fuel systems, with a complete loop to constantly pump fuel to and from the fuel tank. Regards,

Your half way right, the above information if for the electronic returnless fuel systems like those found on Mustangs and Escorts but on the Ranger's and Explorer's they have a Mechanical Returnless system that has a regulator mounted about 2" above the fuel pump in the tank and it runs a higher fuel pressure in the rails at a constant pressure, most of them run 55-64psi.

Why this hi you ask? Because the fuel rails have no return line the fuel has nowhere to go that reaches the injectors and until it is used it just sits there. Well, fuel rails on top of a hot engine tend to get hot themselves and heat can cause the fuel to boil. Like the cooling system the more pressure you put liquid under the higher it raises the boiling point and this is why the fuel pressure is so high on these engines.

Later Doug904.

 

[Doug904]

The 99+ Fords use a pulsed type of fuel pump, because there is no return line(returnless).

The older fuel injection Ford's are return fuel systems, with a complete loop to constantly pump fuel to and from the fuel tank. Regards,

Your half way right, the above information if for the electronic returnless fuel systems like those found on Mustangs and Escorts but on the Ranger's and Explorer's they have a Mechanical Returnless system that has a regulator mounted about 2" above the fuel pump in the tank and it runs a higher fuel pressure in the rails at a constant pressure, most of them run 55-64psi.

Why this hi you ask? Because the fuel rails have no return line the fuel has nowhere to go that reaches the injectors and until it is used it just sits there. Well, fuel rails on top of a hot engine tend to get hot themselves and heat can cause the fuel to boil. Like the cooling system the more pressure you put liquid under the higher it raises the boiling point and this is why the fuel pressure is so high on these engines.

Where does this affect tuning you ask? Well on the normal return style fuel systems with 40 psi we have preset injector values but on the higher fuel rail pressures the values we have will work but they require some tweaking to get perfect. I do the tuning for the X-charger kits for Explorer Express and I make these changes daily for this.

Later Doug904.

 

[CDW6212R]

Hello Doug, how hot would fuel get around the engine?

How is the returnless concept affected by the supercharged vehicles, where there are two 255lph pumps? For a high HP application, what would be the best way to get a lot of fuel to the engine, without pushing two 255lph pumps real hard. I have a 98 Mountaineer, recall, and you had suggested that the return style is easier to deal with high fuel volumes.

 

[jah81592]

So once this is tuned and whatever bugs worked out, are they going to offer a kit for Explorers? Or is this just a one-off?

I will offer a kit if someone will buy it.-j
Contact me for the price. It will be a complete kit ready to go (down to the last bolt)all you have to do is bolt and go,or you can send the truck to me and I will install,of course Doug will do the tune which will be sold in the kit.

 

[raiper]

give us a figure price...im sure atleast one of us are pondering the idea

 

[rocket 5979]

Hello Doug, how hot would fuel get around the engine?

How is the returnless concept affected by the supercharged vehicles, where there are two 255lph pumps? For a high HP application, what would be the best way to get a lot of fuel to the engine, without pushing two 255lph pumps real hard. I have a 98 Mountaineer, recall, and you had suggested that the return style is easier to deal with high fuel volumes.

Supercharged vehicle usually require more fuel then N/A vehicles at any given horsepower. You would have ot be making some friggin BIG POWER to max out dual 255 lph pumps, especially on a return system because of the constant fuel pressure that will be at the rails. Trust me, unless you plan on wanting to race and beat Troll there is no need for anything more than dual 255 lph pumps. Even on a single 255 lph pump you can run a pretty respectable amount of power before getting close to the single pumps limits. What kind of power you plan on making anyways?

 

[BeauJ]

I put in a Walbro 255 lph pump last year and haven't had problems yet. Probably about 330-340 at the crank. The stock pump was bogging out and I could tell it was running lean.

 

[CDW6212R]

Robert, I'm figuring with estimates of 331 CI, 12-14psi boost, with intercooler. Newer Cobra engines are making over 500HP with similar boost. Regards,

 

[rocket 5979]

Robert, I'm figuring with estimates of 331 CI, 12-14psi boost, with intercooler. Newer Cobra engines are making over 500HP with similar boost. Regards,

Yeah dual Walbro GSS342's will be fine for ya. You could even have some room to grow. With decent heads you should be able to make about 500rwhp or so. Rememebr that the modulars, especially the 4 valves, respond on a totally different scale to mods than the OHV engines do. I am not saying you wont be making pretty big power, thats what the cubic inches will help by offsetting any inefficiencies between the two types of engines with more displacement. So you planning a custom centrifugal setup or what are your plans? Oh nevermind I just remembered from the PM's that you plan on the KB2200. Any timeframe as to when all this will be happening for you? By next season I should hopefully (cross fingers) be up and running with my project. It would be really cool to race another really fast explorer sometime. Maybe one day some of us will have to take a road trip and all meet up and have a good ol time.

 

[CDW6212R]

Robert, I found the new KB this Spring. I originally figured I couldn't start for a good six months. I am not yet close with my work vehicle project, so likely I won't be real serious until Winter or Spring.

I am about halfway through with merging my 93 Limited body, with a 99 front clip, body, and 99 chassis. I have 13" Cobra rotors that I'm about to mount 65-82 Corvette calipers onto. A bunch of Explorer enthusiasts are wanting or needing better brakes.

My list is brakes, transmission, exhaust, cooling, stereo, and upgrading fuel system. I have a 97 Explorer engine which I plan to fab the brackets on. I'd love to see some of the people on the forums. Regards,

 

[jah81592]

Ok I gotta a question about the exhaust that you have used. Does or did you vehicle have the duel cats.. if so, would the exhaust that you bought (MAC) would it bolt up without problems... if you didn't go with the turbo?? I am still learning about my 98 so please excuse the ignorance

Thanks
Rage

Mine has dual cats, had to take 10" off the front tubes because my truck is a sport. But if you have a four door you are in luck, direct bolt on! As far as turbo or not the one great thing about MAC is the ball and socket over the axle. So I just unbolted the tail pipe at the ball and socket and connected my turbo "hot side" there. No mods to the cat-back whatsoever. Could have the tail pipe back on in about an hour If turbo had to be removed.

 

[Robz98EB]

James,

I just recently joined the board and was reading about your STS setup. What is the latest word? Have you got the bugs worked out? What are your latest dyno numbers?

 

[jah81592]

I am fixing to join the site. Been meaning to the whole time just have too many projects going on.. I have a few other forced induction projects,along with a 40+ hour week job, and a excellent side business which just gives me enough time to check the forums and go. The pics at the beginning of this thread are all just prototypes and a whole bunch has been changed, such as the crush bends and maf meter location and filter location as well as heat/splash shielding, 90% of my bends are mandrel or "pie cut" style and I am not finished yet. Another reason for such a lengthy process is that I drive this truck everyday and I am not paying for the custom fab I am doing it all my self (I have 12 yrs custom fabrication experience) The new pics will be posted once I join and available for all to see. The install is very clean and professional and anyone looking at it in real life would appreciate the attention to detail. I was not happy with the original prototype crush bends but they were mandatory so I could have a model\"jig" which eliminated the waste from completely handcrafting everything. So this is the reason for the "rough edges" with the original install, this project has been a work in progress changing ideas,engineering and if that doesn't work back to the drawing board to try another change, failure or success! It has been a huge learning experience and everyday I go man I wish I would have thought of that a couple hundred dollars ago. If and when anyone would like for an install or a "Kit" per say it would already have the particulars worked out.
I appreciate the support this website has given and the patience for the dyno #'s but once it is finished I don't think anyone will be dissapointed. Doug and I have had conflicting schedules and his job has had him out of town the last few times we scheduled to finish my tuning. So eventually the dyno #'s will come. I will keep all informed. The only #'s I will be able to keep posted will be dragstrip #'s till Doug and I finish.

 

[ions]

STS Turbo Video

Click here to watch Jah's Truck kick ass on the track

 

[Afboy143]

James, Ever come up with a figure price for a kit?