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Custom upper intake manifold

Discussion in '2011-2014 V6 Mustang Tech' started by JpL4K3, Nov 15, 2012.

  1. V6procharged

    V6procharged Moderator Staff Member

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    looks good phil, hope you get your issues with the spark worked out.
     
  2. 6 Shooter

    6 Shooter Well-Known Member

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    Well, its been a nightmare for 2-3 years. Changed plugs from a 7 heat range to a 9. Gap from .028 to .020. No help. Went to non resistor plugs; no help. Went to Magnecor plug wires; no help. On the dyno, disconnected the alternator and ran off a battery boost box; some help. Went with a 200 amp alternator; no help. Went with a new MSD 48,000 volt coil pack; no help. Was unsuccessful at trying to bypass the MSD DIS-4 spark boost box. Got mad, removed the MSD box and sent it to the factory. MSD said the box was bad and replaced the electronics. Re-installed. The car would not even run past 2500 or up a hill. Got really mad and pulled the brand new out of the box MSD coilpack. Replaced it with the Accel coil pack and shazam, it ran. Sent the MSD coil pack to the factory and got a new one. Shazam, it finally ran.
     
  3. V6procharged

    V6procharged Moderator Staff Member

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    damn man, lot of trial and error and money. i wonder why you are having so much problem with spark and others with more boost are not.

    btw, make an intro thread in the meet and greet for the fellas who arent from v6p.
     
  4. davidcseifert

    davidcseifert that V6 guy

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  5. 6 Shooter

    6 Shooter Well-Known Member

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    Way too much. It took about 6 months and some trial and error. Re-did the water line to the heater twice. Re-did the coolant return line twice. Re-did the idle air controller redirection block twice. Had to modify the bottom of the upper intake several times to notch out areas for the fuel injectors and harness adapters to get it to lay flat on the lower intake. Am also using a phenolic spacer and two paper gaskets between the upper and lower. Had to bench flow the upper and get a shape for the internal runners that would enhance airflow over and above the flow of the heads. Had to add a port to allow EGR gasses to be added. Had to replumb vacuum line ports and sizes to get the PCV hose to fit. Had to redo the air inlet tube several times and change angles to get it to fit and not obstruct with the belt and pullies. The project required a trip to the welder many times, spot welding, and returning to the car to test fit. Found an 80 mm Wilson throttle body which required a '96 5.0 throttle position sensor which came with 3 different colors of wires than the stock setting. Had to data log the throttle position sensor and re-drill the mounting holes to get the required numbers/voltage for idle and WOT. Then, I added a heat shield to deflect radiator heat around the intake tube. Later added the meth injection tube and NOS spray.

    All in all, it was a real pain in the butt and took a lot of time. Cost wise, too much for your pocket book. Oh, and the porting time on the lower intake was around 50+ hours. Then, the porting on the lower 1/2" thick plate was another 50+ hours. Never was sure until the end if it would work out. It did. And, it fits under a stock hood.

    Sorry this post and subject is listed under the 3.7L thread. It should be under the 3.8l / 4.2L bolt on thread.
     
    Last edited by a moderator: Mar 9, 2013