Chingon's Engine Build

[Chingon1]

Got the trubendz exhaust put on today, was really trying to ge the stock mufflers to work to no avail. Ended up using some cheapy turbo style muffler out back. Sounds pretty quiet and really doesn’t drone when cruising… so far. Over all I’m pretty content. Only other thing is the AFR bung is too small so the sensor can’t screw all the way in, gonna have to do some grinding. Pretty much all I need now for the vortech is a 3” universal piping kit and a new intercooler.

 

[KevinVarnes]

Looks nice. How was the fit around the differential? Did they have to modify much to get it to fit?

 

[Chingon1]

@KevinVarnes the fit was really tight there is about 1/2 between the diff and the lower tie brace. They guy had to bend the tub a bit to fit but I feel like it could have gone in without it.

 

[Chingon1]

Did a little porting on the exhaust side of one of the heads today. Harbor freight die grinder and 6” bits. Does a great job cutting and pretty much roughed it up enough where I can do the final with some sanding bits. Overall pretty pumped to see how it turns out.

THE 2-Valve PI DIY Head Porting Thread – Detailed How-To...

www.moddedmustangs.com

All work is based on this post I found on modded mustangs. Pretty much this porting and a valve job the guy claims around 200-220cfm. Compared to the stock 160cfm (I think that’s stock) should make a lil more power!

 

[Chingon1]

Had a lil time today and got to do a lil porting. Pretty much roughed up all the exhaust port side, no valve side just yet and 1 of the intake ports of 1 head.

So far looking decent for about 2 hours of work, still need some more work but I’m happy with it.

Question, would it make sense to port the exhaust manifolds??

 

[XR7-4.6]

IMO not really. I’d say if you do take off the random ring that sticks up in the RH manifold exit and smooth around the hump in the LH that the steering shaft passes through. Beyond that I’d just opt for headers

 

[Zep5.0]

Had a lil time today and got to do a lil porting. Pretty much roughed up all the exhaust port side, no valve side just yet and 1 of the intake ports of 1 head.

So far looking decent for about 2 hours of work, still need some more work but I’m happy with it.

Question, would it make sense to port the exhaust manifolds??


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What are you doing to ensure the ports are the same size for each cylinder. I've seen some guys bend a light wire into an L shape to the desired width of the port so they can cut to that size. And I'm not sure on a 4.6, but most SBF stuff you can port to the gasket size.

 

[XR7-4.6]

Gasket matching is a waste of time.

 

[Chingon1]

@XR7-4.6 i thought so, the manifolds just look too twisted up and narrow for any real work. I did see somebody who had passed away was selling super ported manifolds a while back. Not sure his name but he cut em u pretty big specially the exit side.

@Zep5.0 in the post it shows you exactly which tools, not sure the name but it looks like 2 rods that are able to open and close and then a dial gauge to measure that. First he measures before the intake port, it’s about 1.2” and he recommends opening to 1.4”.

I figured port matching the intake side wouldn’t do much buuuut I will say I’d sleep better at night knowing the ports actually flow into each other instead of hitting on the lip

 

[Chingon1]

Came up today in this C&L plenum and 75mm bbl throttle body for $100 today sweeeeet. Was measuring the dimensions of the underside where it meets the manifold and it’s a tad bigger. Pretty much doesn’t make sense to make it this big if the manifold is gonna be the restriction.

 

[XR7-4.6]

Came up today in this C&L plenum and 75mm bbl throttle body for $100 today sweeeeet. Was measuring the dimensions of the underside where it meets the manifold and it’s a tad bigger. Pretty much doesn’t make sense to make it this big if the manifold is gonna be the restriction.




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Yep, they don’t do anything for performance, but for $100 I’d buy that in a heartbeat if I still had a SOHC. C&L was the only aftermarket “plenum” that looked cool to me, the rest were either way too gaudy (accufab) or cheesy(BBK)

 

[KevinVarnes]

Nice score. Heck yeah, I'd run it for $100.

 

[Chingon1]

@XR7-4.6 i kinda feel like opening up the whole in the manifold side a bit to maybe match it a bit better but don’t wanna ruin a brand new intake in doing so, what do yo think?? It’s maybe 1/8 smaller all around. I like how it has a much smoother entrance into the manifold instead of the rediculous 90 degree angle the stock one has so it might be a BIT better in that regard.

@KevinVarnes definitely gonna run it soon on my bird, just piecing together parts for the vortech install soon.



Still waiting on the heads to come back from the machine shop and I ordered a maurader torque converter and flex plate also.

 

[XR7-4.6]

@XR7-4.6 i kinda feel like opening up the whole in the manifold side a bit to maybe match it a bit better but don’t wanna ruin a brand new intake in doing so, what do yo think?? It’s maybe 1/8 smaller all around. I like how it has a much smoother entrance into the manifold instead of the rediculous 90 degree angle the stock one has so it might be a BIT better in that regard.

Do not do that! The intake manifold is not the restriction you’re looking for, the 4.6s airflow limitations largely boil down to the heads(doesn’t even matter PI or npi) and cams, any limitation the manifold presents is going to be runner length, NOT plenum volume or the smoothness of the elbow(which is all the marketed “plenum” really is), and those long runners are key to the 4.6 feeling even slightly spunky on the street.

It’s much the reason why something like a Bullitt intake doesn’t actually make much more if any real world power than a PI intake manifold setup on a mild to moderate 2V in spite of having a larger throttle body.

 

[Chingon1]

@XR7-4.6 I figured as much, Richard holdner on YouTube did a test with the various PI intakes and it seems like the stock PI is great for a daily driver and even to moderate builds. Unless you’re running a crazy cam and good heads.

That’s the main reason for porting those PI heads I have, according to that article stock heads flow around 160cfm and they get to about 200-220cfm with a 3 angle valve job. Which I’d say would be the best thing that could happen to the engine, besides the bump in compression from the NPI short block and PI heads. Plus I got those heads for $100 also haha.

If everything works in my favor I’m gonna be pulling the engine in a few weeks and installing the heads and vortech in that time. I’d say 1 week is more than enough time to do all that. Gonna move the radiator also and install a boost, oil pressure, water temp and AFR gauge aswell. I’ll definitely keep yall posted.

 

[Grog6]

For an npi, best cheap mod is pi cams,a pi intake and a 2.5" mandrel bent true duel exhaust.
Needs no tune, and it's jy parts

 

[Chingon1]

Got the valve cover gaskets in today, question how come the grommets look totally different? I tried putting the new ones in on the PI valve covers and there ain’t no way them bitches are fitting.

From what I read on TCCOA, the valve covers are different which is why the new 97 gaskets do not fit the new PI heads. Can put the NPI valve covers on the PI heads?? Or do I have to order PI valve cover gaskets??

 

[XR7-4.6]

As long as they’re not Windsor PI heads you can reuse your stock valve covers no problem

 

[Chingon1]

nahh they are Romeo (no Juliet) heads thanks goodness haha

Thank you!

 

[Chingon1]

The time has come!! Started taking the engine apart to pull. Was thinking of lowering the radiator also, does anybody have pictures of where to cut it??

 

[Chingon1]

Pulled the engine today, what a filthy task with 27 year old gaskets GROSSSSS

I noticed the exhaust manifolds have a lil extra lip on the inside that could probably use a lil porting. I’m sure it won’t make huge difference but I’d sleep better at night. Anybody ever do that??

 

[Zep5.0]

Pulled the engine today, what a filthy task with 27 year old gaskets GROSSSSS

I noticed the exhaust manifolds have a lil extra lip on the inside that could probably use a lil porting. I’m sure it won’t make huge difference but I’d sleep better at night. Anybody ever do that??



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I feel like I've heard about a shop that used to port these. So it has been done, but not sure how many have done it without the rest of the porting

 

[1997ThunderbirdLXV6]

@Chingon1
I noticed you replaced your rag joint with a universal joint. How hard was that? Is steering feel very different?

 

[theterminator93]

Preston Smith (RIP) used to port them back in the day; I had a set which I sold to @CDsDontBurn after I installed long tubes. It certainly helps with raw flow potential, but remember the best thing you can do with the exhaust is build it for improved scavenging - focus less on flow.

 

[Chingon1]

@Zep5.0 im not trying to go all crazy, only thinking of hitting the exit side because it looks like it MIGHT get a lil bigger maybe an 1/8 to 1/4 wider. I know it won’t help much but ehh why not.

@1997ThunderbirdLXV6 it’s super easy all you need is a stub to attach it to the column side, I think you can find it on TBSC or maybe @racecougar has one laying around. Again pretty easy, kinda tight but nothing you won’t be able to handle.

@theterminator93 yea I’m pretty sure the scavenging is waaaaaay better with actual headers, unfortunately I’m a broke boii and 1000$ headers are out of the question right now plus supercoupeperformance didn’t have any in stock til mid year. This will have to do for now.

 

[Chingon1]

@XR7-4.6 bill said he had 4v headers in stock except the 2v. I really wish I could have got them, maybe put em on my credit card and paid em lil by lil. But he didn’t even have them in stock til later which sucks since I’m sure the only was they go in is by removing the engine huh, sucks. Anyways this will totally have to do for now

 

[XR7-4.6]

@XR7-4.6 bill said he had 4v headers in stock except the 2v. I really wish I could have got them, maybe put em on my credit card and paid em lil by lil. But he didn’t even have them in stock til later which sucks since I’m sure the only was they go in is by removing the engine huh, sucks. Anyways this will totally have to do for now

Ahh, that makes sense he was able to ship my 4V headers out ASAP. You can get them in by dropping the K member too, that’s what I’m doing

 

[Chingon1]

@XR7-4.6 thank for the tip! Because pulling the engine YIKES haha, maybe if I ever 4v swap it.



Installs the windage tray/oil pan gasket and fully torqued the heads. Also cleaned the engine bay along with the timing cover and head covers.


Also I got this 4” to 3.5” silicon reducer and 4” pipe that’s going on the vortech, kinda like an Anderson power pipe. My question is I’m trying to connect the PVC hoses to an air oil separator and from there I want to get barbs to drill on this intake pipe. Where can I purchase those?? Home Depot??

 

[XR7-4.6]

@XR7-4.6 thank for the tip! Because pulling the engine YIKES haha, maybe if I ever 4v swap it.

A load leveler helps big time with pulling/installing the engine if you don’t have one. I prefer pulling the engine to do stuff like headers or the oil pan gasket etc by far but I don’t own an engine crane, the one I 4V swapped with was borrowed from a friend, and am not interested in buying one(Not for the cost but the garage space they take up!!!). By comparison an engine support bar fits neatly in the rafters

 

[Chingon1]

Dropped the engine in yesterday and fired her up with the new ported PI heads and she sounds spicy

Today took some time but I installed the vortech head unit, clocked it and pretty much ran ran all the intake tubes all the way up to the throttle body. My pops wired up the new slot maf aswell.

Pretty much the only things left are

Run the PCV hoses
Secure the coil packs
Secure the intercooler
Wire up the gauges

Aaaannnnnddddd tune it. Which is gonna be the hardest part.