Something Different for the Ford guys

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Built a new engine this year, and everytime I do a car mod I try to bust out the TIG at least once. I got a bit ballzy this time. Tag along as this might take a few posts.The engine is a ford 3.8 based on a Factory Super Coupe block and Cylinder head castings. We started with the factory forged crank and had it turned polished and balanced to our specs, and had the block line honed. We went with 4340 eagle H beam rods, and a custom set of Diamond pistons. The pistons were coated with a moly graphite on the skirts and ceramic on the tops. Every bearing in the engine was then treated to coatings by Calico. Next went in a custom set of comp solid roller lifters and an agressive billet cam from comp. 3/8 pushrods were used to a set of mini shaft Yella Terra rockers which required custom machining on the heads, rocker bolt size was increased to handle the agressive springs we planned to run. Springs are a nested piece, well over 200lbs closed seat pressure and deep into the 500lbs open. Heads received 1.94 hollow stem stainless intake valves, and 1.6 severe duty stainless exhaust valves, of course topped with titanium retainers. Heads flowed 240cfm intake and 215cfm exhaust at .600"Onto the next post, we'll get into welding stuff I promise Attached ImagesLast edited by neverfastenough; 08-18-2014 at 03:36 PM.
Reply:Heres a great shot of the valve train before we get into the rest......Now the tig was needed, I went to a larger mustang oil pan which required the stock pickup tube to be extended. Youll also spot some more coating here, oil shedding coating was applied to the windage tray. Then some 6061- was ordered up in .500" and stuck into the bridgeport for some one off intake flanges. To end this post, rectangular exruded tubing was ordered, fitted and then tapered into the shape I desired Attached ImagesLast edited by neverfastenough; 08-18-2014 at 03:38 PM.
Reply:Moving right along, actually way along because Im apparently missing half the intake pictures on this computer. The intake shows completion here, with a volume as close to engine displacement as possible. Inside the plenum all ports were got a nice radius entry. Back on the bridgeport again for some custom rails, with 120lb injectors. Also here is a billet ross machine racing throttle body Attached Images
Reply:numbers?  projected HP/TQ@RPM?  Aspiration?  What's it going into?Lincoln WeldanPower AC/DCSmith Oxy/Propane SetupVarious cheap - quality tools..  ;-)
Reply:Dont freak out, theres rail brackets, and water! And a completely custom fabricated set of turbo headers, coated by swaintech, also Tigged by me, and a 67mm precision turbo. Attached Images
Reply:Since it was asked already, a couple of shots of its home. Attached Images
Reply:Now the good stuff!The results:Had some issues initially on the dyno, trial and error sorted it out though. A lot of good minds surrounded the car on the dyno. We had feared we fouled the plugs, so my cold ones where removed and replaced with 103's because it was the only thing available. We fired the car up, e85 in the tank, fuel pump on high, and pulled it with the wastegate spring in only. The car came on strong with the turbo hitting around 3500-3800 rpm 16psi and well into 400rwhp. We continued to dial the car in on 16psi until we were comfortable with the afr and timing, max conservative hp at 16psi was 470rwhp.Time to quit the sissy stuff, we pulled the wg spring and went for something around 20psi. First pull totally raped the tires on the dyno, so VHT was added, and we pulled it again. Well into the 500 range now, the car was laughing at us. We could have pulled it until it ran out of gas and it would have laughed at every bit of it. Time to crank it up.25psi and the vht gave up the grip, it spun like hell. Stuck my 300lb buddy in the trunk, cranked up air bags and we hit it again. Easily cracked the 600rwhp barrier. With some more tweaking we got it to 625rwhp ish with some wheel spin and the 103's getting their arse's kicked. Spark blow out was bad enough that we felt like we had to stop with the boost and call it a day. So with my bud in the trunk we stuck the car in 4th(all previous pulls in 3rd) and went for a glory pull. Unfortunately, I forgot to turn the dyno fans on. Intake air temps reached about 140 causing the car to pull 3 degrees and with the spark blow out it wouldnt let us make any power past 5800, which is silly rpm for this motor, it was loving  7k on the lower boost pulls.Overall we ended the day with 636rwhp 590rwtq. All smiles in the dyno room, the car didnt make one odd noise, not one leak, no smoke, no pops, no stalls. 7000 rpm pulls came right back down and idled with no issues. Coolant temps never even made it to 170 degrees. We all knew it had more in it, full pull, no retard, and a lb or two more boost would have had us in the 700's, but when youre blowing spark youre blowing spark. At this power level the engine is as happy as can be, its really not breaking a sweat. Its a bitchin little combo that should be wicked on the street.(Note: this car was driven 2.5 hrs to the dyno and 2.5hrs home from the dyno) Since I shorted you guys here on pics, heres a video of a 16psi pull, enjoy! BTW you know you have a serious blow off valve when you clean the floor when you let out of itHeres the dyno chart, wheel spin is noticable between 4400-4900 rpm. ACT's started the timing reduction at 5300 and the throttle was lifted when spark blew. By the end of the pull I think we neared 3 degrees of timing retard, which is why power was falling off right before spark blow out. Attached ImagesLast edited by neverfastenough; 08-18-2014 at 03:35 PM.
Reply:Im not a Ford guy, but I definitely can appreciate and respect all of the work you put into that thing! Its pretty sweet and made a hell of a lot of power. Should be fun to tear up the streets in. when is the first 1/4 going to be? What rear end ratio are you running?
Reply:Originally Posted by vettelvr75Im not a Ford guy, but I definitely can appreciate and respect all of the work you put into that thing! Its pretty sweet and made a hell of a lot of power. Should be fun to tear up the streets in. when is the first 1/4 going to be? What rear end ratio are you running?
Reply:Those are impressive numbers for a v6! Nice buildI'm a Windsor fan myself, my last one made 720hp @ 7800rpm, limiter was set at 8400 and it wanted more every time I hit it!Real welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:Originally Posted by neverfastenoughIt's probably coming a month or two down the road, it has a 3.27 rear gear and a stock 5spd trans. I picked up a t-56 6speed recently and will build it this winter. Until then, it will be a delicate process driving this car without sending hard parts to the moon.
Reply:Originally Posted by vettelvr75Nice!!! Are you gonna bump that rear gear up once you get that extra gear in the trans? it is calling for 3.73's!!!
Reply:Nice little Buzz Box ya got there.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:It's the buzzin half dozen!
Reply:Sweet build, that intake is a thing of beauty. Is it a live axle? if so are you considering irs? That's a lot of power for an a$$ light car. Good luck keeping it planted Thermal arc 211iCk flex-loc 150 & 130Clamps, saws & grindersHarbor freight 80 amp inverter
Reply:Originally Posted by Austin BennettSweet build, that intake is a thing of beauty. Is it a live axle? if so are you considering irs? That's a lot of power for an a$$ light car. Good luck keeping it planted
Reply:Yeah I thought about that after I posted, all the cougars & t- birds are irs. Once again cool project, and thanks for posting your progress. Any chance for a burnout video?Thermal arc 211iCk flex-loc 150 & 130Clamps, saws & grindersHarbor freight 80 amp inverter
Reply:Originally Posted by neverfastenoughThe t56 has a .5 6th gear ratio. It's actually going to need 4.56s
Reply:Originally Posted by neverfastenoughBuilt a new engine this year, and everytime I do a car mod I try to bust out the TIG at least once. I got a bit ballzy this time. Tag along as this might take a few posts.The engine is a ford 3.8 based on a Factory Super Coupe block and Cylinder head castings. We started with the factory forged crank and had it turned polished and balanced to our specs, and had the block line honed. We went with 4340 eagle H beam rods, and a custom set of Diamond pistons. The pistons were coated with a moly graphite on the skirts and ceramic on the tops. Every bearing in the engine was then treated to coatings by Calico. Next went in a custom set of comp solid roller lifters and an agressive billet cam from comp. 3/8 pushrods were used to a set of mini shaft Yella Terra rockers which required custom machining on the heads, rocker bolt size was increased to handle the agressive springs we planned to run. Springs are a nested piece, well over 200lbs closed seat pressure and deep into the 500lbs open. Heads received 1.94 hollow stem stainless intake valves, and 1.6 severe duty stainless exhaust valves, of course topped with titanium retainers. Heads flowed 240cfm intake and 215cfm exhaust at .600"Onto the next post, we'll get into welding stuff I promise
Reply:Originally Posted by docweldernfe; that is one very nice ride. looks like a sleeper. no neon colors or fancy graphics and a killer engine. the competition will never see you coming or know what hit them till their eating your exhaust.
Reply:Nice build! As far as the valve springs go, have you considered beehive springs, instead of the dual spring setup now?
Reply:Putting together a similar build in my 86 Daytona
Reply:I love six cylinders. I have a ford 300ci sitting in the garage that I plan to turbo, and a GM 3800 (3.8) that will be rebuilt once the ford is done.
Reply:Great build.  Love the intake.
Reply:As far as the spark blowing out, what ignition are you running? hopefully not a single coil with the factory ignition. An MSD 6a solved my spark blowout issue under boost on my camaro.Welding/Fab Pics: www.UtahWeld.comdddddddddddLast edited by 12345678910; 08-20-2014 at 06:36 PM.
Reply:Originally Posted by docweldernfe; that is one very nice ride. looks like a sleeper. no neon colors or fancy graphics and a killer engine. the competition will never see you coming or know what hit them till their eating your exhaust.
Reply:ummm, WOW!! Nice work, impressive dyno results.Have enough / know enough to be dangerous
Reply:Originally Posted by MikeGyverAs far as the spark blowing out, what ignition are you running? hopefully not a single coil with the factory ignition. An MSD 6a solved my spark blowout issue under boost on my camaro.
Reply:Remember...MSD=Might Suddenly Die.Don't ask me how I know this....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by zapsterRemember...MSD=Might Suddenly Die.Don't ask me how I know this....zap!
Reply:Way back when my buddy Marc was in the final at a BIG bracket race at Atco and right when we got called to the staging lane for the final.......The opposition ran a solo.No time to change it out....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:That blows, its really a shame, is it that hard to make an ignition that lasts?!! These DIS-4 s that I run at well over 500bux, Ive had two come dead on arrival!
Reply:Davis unified ignition. Check them out they might have something for you. Or how about a mag conversion? Not sure of the options available for a v6Real welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:Also was told by MSD rep years ago that batterie chargers will burn up thier electronics for what ever reason... I didn't believe him but it was true, I now unhook the ignition on anything with MSD when it sets and when I charge batteries.Have had no issues since!Real welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:Well with the new MSD, better plugs, and a longer pull (6600rpm) the car put down some respectable numbers 737rwhp and 647rwtq, it has more left in it, I was hoping to pull it to 7k but it was getting too lean. It was a dyno competition so tuning really wasnt allowed other than super minor tweaks. Overall, Im pleased with the engine build, couple recent shots below. 25psi boost btw Attached Images
Reply:That car would get me into so much trouble...Craftsman 90 amp Arc welder
Reply:not just impressive hp/tq #s, but to be able to get a gasser bottom end to withstand 25 # of boost, nicely done.Have enough / know enough to be dangerous
Reply:Originally Posted by lighttekkuThat car would get me into so much trouble...
Reply:@neverfastenough Yeah for sure. I had an eagle talon tsi awd putting out less then 400 go and the local coppers couldn't keep up at all. Had a couple times where I thought I was gonna die in it. Glad I got rid of it. Was a fun car but not worth dying in. But that was when I was in high school. I've come to realize that driving like that isn't a good idea unless you're on a racetrack. But sometimes I still miss it.Anyways sub 400 hp with AWD was freaky around the corners, I can't imagine 700+ with RWDCraftsman 90 amp Arc welder
Reply:Oh the memories , hanging out at the gas station, talking smack about car's we would never drive or own.Circling around Micky D' parking lot trolling for races or chicks . Dodging the law on the way to a long straightaway . Best place was a stretch I 84 that was a dead end spur  about a mile long . but some one had to go in  first and check for sleeping cops.gxbxc