2006 Intake & Carburetor Modifications
Updated 3/6/06
Well, have decided to finally get started on the turbo installation. Jacked the car up and leveled it out today so I can also install the 8 point cage during this process. I dropped the Tremec 3550 out and took it to Andy at American Mustang, he's going to sell it to another customer. I picked up a brand new Tremec TKO 600 last month and will be installing that with the new motor. Anyhow will be starting on the cage fabrication as well as the exhaust/turbo manifolds along with the exhaust out of the turbo's.

I have decided to go with 4" exhaust from the turbo's as far as I can and then transition down to 3" the rest of the way out the back. Picked up all of the weld ells & exhaust tubing to fabricate everything from the motor to the turbo's and then back around under the car by the transmission. Will also be installing the Fays2 Watts link while I am installing the cage and tieing everything together under the car. Hopefully that will help me keep this thing on the road when I start learning to road race!!LOL

Anyhow, snapped a couple of pics of how the old motor looks right now, the new TKO 600 & the car with the new hood. It will be cool to compare them with the new motor and turbo setup.

Updated 3/7/06
Installed the heads, lifters, pushrods & rockers today on the new motor. Got them all adjusted, everything went together great.

Updated 3/14/06
Started port matching the Weiand XCelerator intake to the AFR 205 heads yesterday. The intake ports on the stock heads measure 1" x 2", the AFR ports are 1 5/16" x 2 1/8". The porting is taking a little while, about 40 minutes a port. Doesn't seem like much, but that's almost 40% more area. The first picture shows two of the ports before I started(well I barely hit the one on the right when I remembered to take a picture). The second shows one port done, then the next pic is with both done. In the next pic you can see the scribe marks around the ports prior to any work being done. The next pic shows the intake manifold before porting, after porting & compared to the AFR 205 head ports. The last pic shows the top of the intake where I have cut the grooves for the air seal passages to pump air to the carburetor throttle shafts. I also took some material out around the edges of the plenum to match with the bores on the carb spacer. Overall I am pretty happy with the results so far, hopefully this will help the engine breath! When I am all done I am going to sandblast the top of the intake to clean it up and then clear coat the intake manifold.

Updated 3/23/06

Well I have finally finished all of the port matching on the intake. Also decided to mount the PCV valve in the back of the manifold similiar to the mid '90s 5.0's. Picked up the grommet & PCV valve for a 5.0 and drilled a hole to mount it behind the carb. I am going to build a heat shield/baffle for the valley of the motor to try to keep the hot oil from splashing onto the bottom of the intake. This should also make a nice area for the PCV to pull from without having so much oil misting around like it does inside the valve covers. Anyhow, once I finished all of that I sandblasted the intake and gave it a nice clear coat top & bottom. I like the natural finish on most intakes, but hate how it stains so I thought I would try this. I ended up with 13 hours into the port matching & modifications to the intake including the painting. I like the way it turned out, hopefully will be easier to keep clean.

I also modified the new phenolic spacer for the air feeds to the carburetor shafts and also for the PCV. You can see the PCV valve & barb fitting in the one pic as well as the small AN fitting for the air feed to the carb. Still waiting for the intake manifold studs and fabricating the heat shield. Then I can get the top of the motor sealed up and move on to the next project.

The pics below show the finished carb with the ProForm main body. I have heard great things about the ProForm main bodies, and I am hoping the screw in air bleeds come in handy when it's time for tuning. Besides the main body the following modifications were done to set it up for being under boost. It has .150 needle & seats installed, nitrophyl floats, rear jet extensions & quick change float bowls. I removed the back fire protection and sealed the plugs on top of the metering bodies. The metering bodies were modified by Bigg's Carburetors to flow more fuel also. I have also done the modifications for the air seals & O-rings I cut in the throttle shafts. All of the modifications to the carb & intake for the turbo's are completed and you can see it all together in the pics below. There is a great website that covers the modifications for using a Holley double pumper on a blowthru turbo setup at Andrew Slater's Hanger 18 site. He shows everything I have done in the carburetor section of his website except the air seal modifications. You can see how I did the air seals for the throttle shafts if you look around on the his site for the page on his Vega. It's great information, check it out. Next I will probably get the front of the motor put together and start fabricating the exhaust manifolds.

2003 & 2004 Intro Page/Page 1
2005 Clutch & New Motor/Page 2
2006 New Motor Modifications & Assembly/Page 4
2006 Turbo Exhaust Manifold Fabrication/Page 5