supercharged 5.0 true fire 98 explorer sport

[vroomzoomboom]

so finally after waiting 2 weeks i picked up the intake from the guy who welded it. i would have taken it to either dono's guy that he found to do alumn. or the guy that repaired the mount that is on the truck now, but my neighbour owed me a favour for doing some work on his truck and this was the guy he dropped it off to. not much of a favour return, i ended up paying for it, and waiting as long as i did but its back now, and in time for a inferno of a heat wave we have coming this week. looks like this will once again have to wait until the weekend when its cooler rather being able to work on it this past week when it was cool out.

i had him weld up the dimples between the runners, then build it up the edges so they can be milled flat. that was the top plate will have something flat to sit on. next is to rip the runners off then start cutting and drilling holes on the alum plate.

 

[vroomzoomboom]

WARNING

the next post shows graphic images of new innocent parts being cut up and sacrificed
viewer discretion is advised

finally today i got to cutting the intake up. there was a few tricky spots, but i butchered threw them!

also wanted to see just how wide this blower is now that i am able to lay it on the intake. pretty sobering thought, thats for sure. then again, the plate that mounts the blower will be a tad bigger, and i already knew i was going to be hacking away the blower mounts, and a little off the sides as well. funny because the m112 doesnt look that wide, and yet it is!

 

[vroomzoomboom]

despite it also being 41C with the humidity (thats 106F for those that dont know) i also started milling down some of the left over runners flush to what will now be the valley pan. all of this was done with a saws all, a alum zip cut wheel on a 1/2 grinder, and a rasp file.

was out there for around 5 hours or so until i said enough. was starting to sweat so much i thought i would short out my grinder. maybe later on tonight i might go back out there and do some more, and hang out with the mosquitoes. the 2 front ports are going to be a ***** to do because the water jacket is like RIGHT there, so i have to be careful on how i cut.
so for now, i am going to go and pass out from heat stroke for a while. thank god for central air!

 

[gmanpaint]

Point of no return Now! Well, for that intake at least. Lol

Hope it works out. Take care in that heat, we're not spring chickens anymore.

 

[Dono]

I see what's going on now. Couldn't see it with the sharpie marks.
I can't believe you were out there working in the heat. I'm in Regina, and trying to get a few things done outside. I tried, and quit. Back at it in the dark, way better ( moving big rocks, digging, etc). Gman, your right. Now that I'm in my 50's I can really tell I need to be more careful. Getting od blows, but better than the alternative.

Intake looks awesome! Nice work

 

[vroomzoomboom]

Well it is 130 in the morning right now and I just finished doing three runners on the other side. It goes quite a bit faster when you figure out a couple of little tricks to get in there with a saws all and cut closer to the wall of the intake.

I still have to do the front two runners which will be a total pain in the ass. However that will be tomorrow’s job. I’m still trying to figure out how to do them because there are a few tough spots to get into and the carbide I bought isn’t long enough. Luckily I have a old cylinder head porting kit hear that I will probably end up having to break out.
As for the heat I think he might be immune to it now. The place I am back working in at work is a tin building with no air circulation in it. However the nice part about it is I can score unbelievable parts. Like the 410 explorer differential I have sitting at home now, A third generation explorer headlight switch that will end up going to Simon, A pair of cruise control switches that I got out of a lincoln that should fit into Don‘s Limited, A 4406 shifter linkage That another member needed, and a first generation window module that I can do another one touch down on a passengers side window and a billet grille like evil has that will be going into my kids truck. And that’s all just with in the last week LOL

 

[gmanpaint]

Right now, that is the strangest looking intake I have seen. lol

Thinking of what else could work to cut with.....Would a 2" cutting wheel on a die grinder reach to cut with? On job sites, we use those electric multi tools for hard to reach spots. They have a blade attachment for just about any material.

Wanted parts delivered to your work. That is a nice type of job perk.

 

[4pointslow]

That intake looks awesome!
You should have a mold made from it to have a bunch cast. New Kit!!!!

Are the 4:10's going in Evil?

 

[vroomzoomboom]

Right now, that is the strangest looking intake I have seen. lol

Thinking of what else could work to cut with.....Would a 2" cutting wheel on a die grinder reach to cut with? On job sites, we use those electric multi tools for hard to reach spots. They have a blade attachment for just about any material.

Wanted parts delivered to your work. That is a nice type of job perk.

dont really thing you can call it a intake anymore. i just say its now a valley pan.
i know what your talking about, you mean those small cut off wheels you put on either a dye grinder, or dremel. that too is to big or clumsy to fit into there. even using a small blade on a dremel will hit the back side of what i am cutting. this will need to be cut out with a carbide and a crap load of patience.
its the only job perk lol. i dont go to the wreckers, the wreckers come to me! if there is something i need, and can hold out on, it will evenually come there. crappy thing is it wont be long term. when all the cars back there are process, i will be taken off that, and given some type of crappy job. they only have me back there because they know i dont need to be babysat. i will truely say management doesnt exactly like me, and the feeling is mutual on my end!

That intake looks awesome!
You should have a mold made from it to have a bunch cast. New Kit!!!!

Are the 4:10's going in Evil?

i tried that once. i was going to make about 10 mounts for the m112. the kit was going to have a mount, coil mount, pulley bracket, all the bolts and spacers, intake elbow, even instructions and was going to sell them for around $800. everyone thought that was too high (one guy even said when i lower the price to $400 he would take one). so that will never happen again. most people are clueless when knowing how long something like this takes to make. just chopping those 6 runners off and filing them flat took about 6-7 hours.
as for the diff. that is a spare. if evil ever blows up the rear diff, i have one. the spare isnt a trac lock however. that and my kids truck is a 4.10 as well, so if he ever blows his up (even though he doesnt 4x4 it........to my knowledge....) i have one here as well. and 2 front 4.10's lol. or if don ever wants to see if a 4.10 would make a difference in his truck, we can swap them for him to try

 

[vroomzoomboom]

couldnt do much today. i have changed the sheds name from the gas chamber to the incinerator due to this "heat wave" we are having up here lately (heat wave my ass. i though i saw satan today buying a air conditioner). i picked up dons old block today because i will need it for mock up making this mount. went out there at around 11pm (right now as i type this its close to 1 am and it feels like 38C or 101F GUHA!) and put cellys old crank and heads on it. as i was sitting there basting in my own sauce, i figured i would plop the valley pan, alum plate and supercharger on it to get some motivation only to discover my first problem....well two problems.

when i put the supercharger on the plate, it sat too high in the front. in otherwords, it didnt sit flat like its suppose to.

figured the dowel on the right side was holding it up, but it wasnt.

i forgot because i will be using a m112 snout on it, not only is the bolt pattern different at the very bottom, but so is the shape. no big thing, will have to shave it down.
then the valley pan also didnt sit just right either. i figured that the welds on the edges of the intake were holding it up and need to be milled down as well. i was sorta right

the edge of the heads are holding it up not allowing it to sit flush. that too will be dealt with when the time gets close (in that picture i tilted the intake so you could get a better look at what i was talking about). so tomorrow or i should say when i get up in the morning i will have to find a longer carbide so i can keep cutting into the last 2 intake runners. i have a bad feeling i might have a hard time finding them. when i went to pick dons motor up, i had asked dimas if he had any he could sell me. he only had 2, and was going to lend them to me and went on to tell me he has had bad luck finding them locally and has had to order them and wait for them to come in. when he told me that i didnt want to take them. he was going to be doing some port work this week and i didnt want to slow him down. good thing i am off tomorrow.

 

[4pointslow]

put some old head gaskets between the heads and block to simulate how the heads will really sit.
If that makes sense..

 

[Dono]

yea, head gaskets and intake gaskets might change the angle quite a bit. Hopefully, anyway.

 

[vroomzoomboom]

put some old head gaskets between the heads and block to simulate how the heads will really sit.
If that makes sense..

yea, head gaskets and intake gaskets might change the angle quite a bit. Hopefully, anyway.

i did think of that. i saved a set of old intake gaskets, but goof'd and tossed the head gaskets.
i have called everywhere today trying to find a long burr so i can grind out that last of the ports, and nobody has any stocked. looks like i will be at a stand still for a bit now....

 

[Dono]

maybe Dimas has my old ones still laying on his bench?

 

[vroomzoomboom]

was able to call the shed a shed today. cooled off, so out the door i went and finished pretty much all the major grinding

the front ports were as i said a major ***** to do. number 1 cylinder came out ok

however i might have to live with number 5. there is a lot of meat to get out, and i really dont have the tools to do it. after all, this was all done with a grinder, saws all, carbide attached to a drill and a flat rasp file.

at some point i will go back in and clean up all the file scratches and do some more blending, but the major part is done. i will have to get some more alum for the ends of the intake and get them welded in, then i am going to see if my buddy can machine everything flat. once that is done i can start working on the plate that goes on top of this and figure out where the supercharger will sit.

 

[ahodges]

So Tim, what was the purpose in welding along the edge at the point it meets the heads?

 

[vroomzoomboom]

im going to try and explain this without confusing evryone.....even myself

the parts in red need to be built up because they are on a lower plane then the runners. you want it all to be a equal plane from front to back. then you weld the sides in blue up because you want the height of the inside of the intake (closes to where the carb would sit) to match the side that mates to the head. the reason for that is you will machine them flat to match the height where the bolt holes are so when you lay the plate the supercharger sits on into it, it can seal. otherwise, you would have the edge of the intake which is i will say a 45 degree angle trying t meet up to a 90 degree which is the plate. if i havent explained it clearly (and i know i havent because its hard for me to do without you standing here) think of your EE set up. there is a lower part of the box that bolts to your intake, and a plate that bolts to it. if the lower part of the box had a 45 in it all away around, and the plate is flat trying to sit onto it, it would have a smaller area to seal because it would be on a sharp point. also this way, when i seal it up, there is less chance imo that i will goop up the heads with silicon as well.
i hope this all makes sense. if it doesnt, it will be more clear as time goes on because i still have more that has to be done to the valley pan.

 

[Dono]

I wanna see how the intercooler will fit once the intake "walls" are up. Looking great.

 

[vroomzoomboom]

I wanna see how the intercooler will fit once the intake "walls" are up. Looking great.

you made me curious about something so i just went outside to do some measuring. the m112 thats on evil right now. measuring from the bottom of the lower intake to the top of the blower stands around 13 inches. give or take a haft inch. the way the m122 sits right now with the plate not sitting flat on the valley pan, and the blower not sitting flat on the plate, 9 inches. looks like daddy has lots of room for a intercooler! my biggest worry right now is how the fuel rails are going to fit. even with shaving the mounts flush to the supercharger casing, its going to be tight. if only this was a 351w block, there would be plenty room......hmmmm....351w block, stroked to a 408 in evil.....hmmmmm....

 

[gmanpaint]

Starting to think, having an alum intake custom made to fit, would have been easier. Yeah I know, $$, but at this point, meh, just $$.

Oh, welcome to the 100 page mark!