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supercharged 5.0 true fire 98 explorer sport

Post number 3431 has been selected as best answered.

hi everyone, my name is tim . i live in selkirk, manitoba, canada and as if this date that i am posting this, i am 36 years old.

i bought my sport in jan 05 from a local ford dealer. it had 111,000KM's on it. this is the second sport i have owned. it was sitting on the lot for about 8 months before i came along. i am the third owner (i was able to track down the person that traded it in, and they got it from a friend, who bought it new in 98).

i started to do a few things to it after i first got it, then i found this site, and all hell broke lose! i've never been satisfied with something the everyone else has, so i started to tinker with it even more.

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mods include

interior

installed factory tilt, cruise, overhead console, auto dimming mirror, full length console, with a message center (it didn't have these from factory).

white face with blue flames indigo gauge covers (they light up blue)
blue l.e.d. everything
white l.e.d. interior lights
Kenwood DDX392 Touch Screen Head Unit
alpine 4 channel amp (all four speakers)
boston acoustic front and rear speakers
alpine mono amp (for sub)
2 12 inch jl audio subs
rockford fosgate cap
passenger side one touch window down mod.
custom transfer case shifter
tripple a pillar gauge pod, housing autometer boost, Innovate LC-1 wideband, and oil pressure gauge
12v power inverter with 120v plug in a 2 usb plugs built into the center console

exterior

BMW E46 projectors, mounted into stock housings using clear lens
6000K HID head lights
angel eye "driving" lights, with 8000k h.i.d.'s
clear parking/corner lights
billet grill (powder coated by Turdle)
blacked out ford emblems
custom front steel 95-98 bumper, with 4 inch round tubes welded in for driving lights
shaved radio antenna
shaved roof rack
black euro tall lights
l.e.d. license plate lights
smoked out 3rd break light
lund rear tailgate spoiler/wing (formally from the truck "blackjack" owned by EF member Spas)
hand made roll pan (made from 3 1/2 rear bumpers, with 1/4 inch diamond plate on the top, and it is removable)
aluminum T/A differential griddle/cover (powder coated by Turdle)
Motegi Mr107 20' rims
goodyear wrangler hp p245/50 r20
1 1/4 wheel spacer in the rear, 3/8 in front
and most noticeable, black with blue pearl paint, and blue true fire (ground effects are black with blue pearl as well)

Suspension

2 inch lowering blocks in the rear, reverse TT in the front (2 inch as well)
Explorer Express rear sway bar
4 door leaf springs
rancho rs9000 adjustable rear shocks
03-05 sport trac spindles with drilled and slotted rotors

performance

5L swap
347 stroker
TFS twisted wedge alum heads
comp gold 1.6 rockers
comp cams CCA-35-556-8 nitro cam
heavily modified edelbrock victor jr air gap intake (which serves as a valley pan now)
eaton m122 supercharger (metco 2.70 pulley, and ASP 8 rib 7 1/4 crank pulley) with custom made mount with bell intercooler core
8 rib serpentine belt conversion using pulleys from a 7.3 powerstroke
custom made 3 1/2 inch throttle body elbow
accufab 75mm throttle body
4 inch intake pipe
PMASS MH90 90mm Universal 3000 KG/HR MAF
amsoil cone filter
F.A.S.T. 60lb injectors
edelbrock fuel rails, trick flow specialties fuel pressure regulator with summit racing fuel pressure gauge
walbro 255lph fuel pump
1/2 inch steel braided fuel pressure line from tank to rail using 8AN fittings
torque monster headers
2 1/2 duel pipes with flowpro duel in and out 2 1/2 single muffler
accel extreme 9000 ceramic 45 degree plug wires with boot protectors
4R70W w/2600 stall with J mod
tuff stuff 200a alternator
tuning made possible with sct pro-racer package, and tuned with major help from member [MENTION=102869]Dono[/MENTION] and [MENTION=81804]4pointslow[/MENTION]
flex a lite duel 12 inch electric fans
big 3 upgrade (4 gauge wires)
meziere innercooler water pump
2 froozenboost innercooler rads

Transfer case

4406 manual shift from a 97 F150
modified stock trans cross member to accept 93 mustang 5L polyurethane tans mount
double cardan rear drive shaft

because of all the "fun" i had doing the bodywork, and some other things to my truck, i have nick named it "evil dora" or if you like, just plane "evil"!
and now the thank yous

my buddy gord leiss, who let this thing sit in his garage for 3 months while i did the body work to it. he also gave me a hand with some of the prep work, and painted it for me

kevin willson for doing the true fire http://affordableairbrushing.ca/

Joe Bukoski for letting me do the 5L/4406 swap in his garage

now people from this site, weather they knew it or not, they helped

BIG THANKS to tara a.k.a. explorersport77 for pictures of her truck. wouldn't been able to build the roll pan with out them!

ExplorerSport77's X "Hotness"

jon a.k.a. Turdle for selling me some real swanky rear shackles, as well as powder coating the diff cover and sending them up to canada. as well as much needed info on v8, and 4406 swaps as well as doing the grill and showing me how its done.

don aka dono for the help with the tuning, and wideband, as well as the supercharger

andy aka ahodges for some parts, and any help i needed for all the go faster goodies

5.0 swap - w/ 4406

jad2411 for finding me a link for my hidden antenna

ryan a.k.a. MustangP51 for doing his write up on making l.e.d.'s for interior lights, and how to make projectors

P51's HID Headlight (Projector) and Fog Conversion (PICS)

and N3ELZ cardomain page for L.E.D. switch and cruise pod mods

http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-6
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-12
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-23

bob a.k.a. rwenzing for showing me speedhut's sit for the gauges

Gauges, Custom Gauges, Tachometers, Speedometers, Shift Light, Pod

Buzz4x4 for his write up on blacking out ford emblems

How to Make Your Own Custom Ford Emblems

the late aldive for his write up on one touch down passengers window mod

http://www.explorerforum.com/forums/showthread.php?t=141027&highlight=touch+passengers+window+mod

BIG COUNTRY, for his write up on how to install a auto dimming mirror

http://www.explorerforum.com/forums/showthread.php?s=&threadid=84968

BIG COUNTRY, 98formulaLS1, and Ryon40 for there write ups on how to install a message center

http://www.explorerforum.com/forums/showthread.php?t=225017&highlight=BIG+COUNTRY
http://www.explorerforum.com/forums/showthread.php?t=80670&highlight=message+center
http://www.explorerforum.com/forums/showthread.php?t=245085&highlight=Ryon40

MountaineerGreen for his 4406 swap write up and "Custom" Driveshaft for a 4406 and 4" Superlift on the Cheap " (even tho its lowered

http://www.explorerforum.com/forums/showthread.php?t=166726&highlight=awd+4x4+swap
http://www.explorerforum.com/forums/showthread.php?t=185232

Simon, aka blueka for his "pickle" thread, and help anytime i picked the phone up the phone on the 5L swap

http://www.explorerforum.com/forums/showthread.php?t=271813

Jon, aka 4pointslow for any MAJOR technical advice i have needed

http://www.explorerforum.com/forums/showthread.php?t=219092

i wish i could find who did the write up on the overhead console install, but here is the link

http://www.explorer4x4.com/overhead.htm

Russ aka NICE59FORDF100 for his help on the wiring, and what to watch out for electronically.

hopefully one day, i will be able to help people on here just as much as the people that i have mentioned above!

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plus you know you have done something right when.....

your truck (as well as corkey) wins truck of the month

http://www.explorerforum.com/forums//showthread.php?t=296023

is the feature truck on the fun hump day radio show (starts roughly around the 30 min mark)

http://explorerforum.podbean.com/2011/03/23/19-vroom-zoomboom/

and you drive 26 hours ONE WAY to the carlisle all ford nationals in june 2010 and 2011, and grab second place in the s.u.v. all category!

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then in 2014 you go back to the same show you have been to 5 years in a row (nothing by most, but its one hell of a long drive) and take first!

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its been a busy weekend. got the heater core done, i also did some cleaning and moving around my hoard pile of parts in my shed. today i was going to kick back and take it easy, then my phone rang which lead me to go get this.

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i got it fitting real nice, but when i put the weather strip on, and the latch, it kinda threw it out. i also didnt notice, but i will have to make a extension for my pinch weld at the cowl. to big of a space. i will have to fiddle with it some more, but i will do it later.

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if you look at the back edge, it sits a little high. will deal with that this week when i have some more time.

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also when i went to pick the hood up, he had a car sitting in the both with a cover on it.

"guess you didnt see this the last time you where here"

"what is it?" he rolls the cover back and there is my bother in-laws fathers 62 t bird.

"they are coming to pic it up today, should be here soon"

i forgot his dad is selling off his cars because they have their house up for sale, and no longer have storage. so if you are able, on Thursday it goes up on auction.

 



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Progress looks great!

I'm really interested to see if you can get the back of the hood to sit down. I tried everything I could think of and settled for a little offset on mine.
 






Can you slot the hinges where they bolt to firewall and move them down 1/4”?
 






∆ makes sense
 






Progress looks great!

I'm really interested to see if you can get the back of the hood to sit down. I tried everything I could think of and settled for a little offset on mine.
Can you slot the hinges where they bolt to firewall and move them down 1/4”?
that was the first thing i did. it did help. i will take the weather strip off, and bend the pinch weld down a little and see what that will do next.
 






that was the first thing i did. it did help. i will take the weather strip off, and bend the pinch weld down a little and see what that will do next.
It looks awesome! I'm sure you will get it sitting and looking the way you want soon.
 






no word on the flame guy. im good with that at the moment because it got busy here for me real fast.
bought another truck to flip, however i may have screwed up on it, shes got a lot of barnacle that will need fixing before it can be saftied, not awesome. also the amp in my 07 ranger decided to leave the chat as well. good thing for me i have a buddy that works at a auto video store and does all the car audio stuff.
however, after waiting a month, my mount is back from the machine shop. what sucks it they couldnt move my IAT sensor. they were going to drill and tap a hole , but it would have been right on the weld and near the cooler. i said if hes not sure thats a good idea, dont do it. i bought a bung for them to weld in, but it just melted into a ball, so that was the end of that. he did mill the bottom of the mount, but had to stop short, or my holes for the injectors would have opened up to big, and they would have fallen into the bottom intake. it did make a little difference, but not totally flat.
started to do a little on friday, then saturday was rain (surprise on a may long weekend here.....) today however was nice so i had at it.

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i made a few more small changes. i moved my coil driver down below the supercharger. this gives me a little more room up top so its not as crowed at the back of the supercharger. i as used a gasket this time at the base where the supercharger sits on the mount. trying to separate the the 2 was not a fun thing. this also makes it a lot easier putting it all together and apart because its not as heavy (and i aint get'n younger either). i am using arp bolts instead of the grade 8 ones. was a little on edge the last time when i was torqueing them down (35 ft/lbs going from the mount to the head, and if that bolt broke, off come the head, nope. no)
when i made this mount, i kinda also made one error and that is at the back where the outlet for the cooler is. it comes out to a 90 degree fitting, then a short hose, to a joiner because you couldnt unscrew it before. the problem was that hose is right above the back bolt on the passengers side of the intake, and no matter what i would do, i couldnt get a socket on it. now putting it together like this, i can put the hoes on later, and torque that bolt, hopefully no leaks either. i can also torque the supercharger to the mount now as well......right up until the bolt gets loose before the torque wrench clicks........its staying that way because i am crazy like that. i will check for leaks tomorrow.

speaking of, i didnt get as far as i wanted today, but further ahead then i was yesterday. hopefully it will be nice out so i can finish it up, scale the new IAT check over everything to make sure all is good, then set a appointment with moe's speed shop to continue with the tune.

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:mad:

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leaking intake gasket make tim something something.

so its back to looking like this again.


called the guy who built the motor for don, and also machined the lower intake for me. had said to use some aviation gasket sealant or yamnar gasket seal on the gasket because the intakes can or will warp overtime. i can see that after what i have done with it. looks like i wont be driving it this weekend. i also discovered a way to test the motor without it being completely together, so i will be doing that for now on as well.
 












I hate walking backwards. Crap .

Is it out of line to smear the head and intake surface, with gasket in between?

i would say no because i do believe thats what he was telling me to do. never done it before, but hey that dosent mean it wont work. i will find out tomorrow or the next day when i try to put it back together.
 






Double up the gasket? Thicker gasket? Yamabond? That stuff is like a permanent gasket

Geeze man! At least you know where the issue is and can see it with your eyeballs that usually means it can be fixed
 






Double up the gasket? Thicker gasket? Yamabond? That stuff is like a permanent gasket

Geeze man! At least you know where the issue is and can see it with your eyeballs that usually means it can be fixed

not a big fan of doubling up gaskets.

i did get that gasket sealant today, its this stuff.

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it looks like baby $hit, almost smells as bad to.

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this probably would be wrose for getting it on your hootus, then herculiner, major sticky stuff and i can see it not being any fun getting it off any surface. put that on as well as the lower intake, and mount. will let it sit overnight and retorque. hopefully this solve my problems.
 






I've used that on different things and yes it works well. I just don't recall a temperature rating on it. I stays pliable and isn't that horrible to clean up.
 






That looks similar to an old sealant product that was popular in the late 70's. I hope it's better, when it's old it is very very hard, and hell to scrape off. I used it for sealing a water pump twice(Cleveland), and a thermostat gasket at least once. Back then there were not many RTV choices, those were just coming out. We used Spray Tack by Permatex a lot too, it was great for the WP gaskets, after I learned how hard that brown stuff was to get off.

If the two mating parts are well fitted together, no major gaps, nice even gaps, then any Ultra RTV should seal it well. I would again double check the fit of the intake to the blower plenum, look at it all very closely. I hope you get it sealed up soon.
 






Use this stuff its great

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Indian head gasket schellac

Permatex makes it! Can’t use an Inian head for Marketing anymore otherwise your head gasket glue maybe considered racist
Is the old brown stuff you are talking about

They still sell it! I have some

It worked wonders pita to scrape off, but it fixed any leak basically glueing the metal bits together lol


I’m worried that any rtv or sealant will blow out of that hole under high boost
Which is why I was thinking of stacking gaskets, to fill the gap. Nobody wants to stack gaskets but it does fix machine edge problems!
 






My upper and lower intake
The intake lid
Blower
All rtv
The Moddbox r&d guy said that gaskets were blowing out lol

I emailed them asking for gaskets and he told me no lol

I'd hate to see it leak again
 






I've used that on different things and yes it works well. I just don't recall a temperature rating on it. I stays pliable and isn't that horrible to clean up.
im going to say it should be ok temp wise, the engine builder that dono used for this motor, and he has also done work for my other motor recommended it, and he is very well known in these parts lol.

Use this stuff its great

View attachment 452718
OH HELL NO! lol. i have used that in the past. it works well. actually too well. just want it to seal, not liquid weld itself together lol.

Indian head gasket schellac

Permatex makes it! Can’t use an Inian head for Marketing anymore otherwise your head gasket glue maybe considered racist
Is the old brown stuff you are talking about

They still sell it! I have some

It worked wonders pita to scrape off, but it fixed any leak basically glueing the metal bits together lol


I’m worried that any rtv or sealant will blow out of that hole under high boost
Which is why I was thinking of stacking gaskets, to fill the gap. Nobody wants to stack gaskets but it does fix machine edge problems!

fair enough. when i tested the motor for leaks, i know i was above 13lbs (cant say for sure how much but was more then what it would make in boost). the last time i had this problem i was using a buddys home made smoke machine. he had used a bbq regulator to bring the pressure down. i used a old valve that i had on a air sanding board. i wanted to go a tad overkill that way i knew i wouldnt have problems down the line.
 






after ark like rain for the past 2 days it was back to smelling resin cure. i think however those 2 days were a good thing. i think one of the problems was i wasnt letting everything dry before smacking air at it. this time it had 2 days to dry. pushing air into it, and doing my little bubble test, snowed no leaks. the next was putting water in, once again success! with that all said it finally let me win one.

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was going to start it when i forgot i have to scale the new IAT. with that, i needed my laptop.......which has been sitting since october. so now it waits till tomorrow. no big deal, fat guy was hungry anyway.
 



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she crackled to life tonight. had to get a buddy to help scale the temp sensor. also forgot i had to do a map sensor as well (drop down menu, easy one).
for whatever reason my fans were kicking on as soon as i turned the key. will have to look into that one, also still getting high IAT's. was hoping the new sensor would read a little different, but nope. was 56F with the hood open, after idling long enough to burp the coolant, it was reading around 145F for IAT's. that sucks. it also is idling on the high side. around 950rpms. going to look and see if i have a vacuum leak someplace else, or if the throttle blade is hung up. it also will idle fine for a min or 2 then die for no reason. it wont start unless i turn the key to off, then back on again. im sure that is a tuning issue. cant remember if it did that before or not. but its running now, and i can move it.
 






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