5.4 3v intake mods

[billfisher]

http://home.att.net/~bill.fisher/IMG_1685.jpg

the first photo shows the airhorns. i cut the intake with a dremel and a heavy cutoff tool. i took 4 passes making sure to follow and not thicken the cut. i will drill and tap the flang area for screwing it back together. silicone will seal it. the original process friction wleds it. there is no way to bond it. bayer makes a solvent to aid welding, but this nylon resists solvents.

http://home.att.net/~bill.fisher/IMG_1686.jpg

the second pic shows the area that is covered by a plate and holds a weight. this is the area for primary cutting. i will fashion .050 plate to seal the area. it will also screw into the manifold. sealing with silicone. the outside of the runners will be left for the screws. sealing gaskets on the screws takes care of sealing.

http://home.att.net/~bill.fisher/IMG_1688.jpg

this is the top of the plenum. i will cut the runners to just under this area.


taking this bad boy apart requires patience. i burned my dremel up doing it. a lot of drag. the plastic melts real easy. the outside bottom has a large flange area. the screws will not intrude into the inside of the manifolds. no leaking issues there. over all this is an easy mod. now for runner length.

for a 330cuin. motor with a torque max rpm of 5700, the cross section needs to be 2.45 inch square, and 14" long. this is from the valve head. i am going to cut and flare it at 13".

 

[Black2001GT]

Wow, talk about precision.

The shorter intake runners will move the max Torque to what RPM?

 

[mrvax]

Wow, talk about precision.

The shorter intake runners will move the max Torque to what RPM?

I'd guess it would move the max TK to a lower rpm.

 

[DBMSTNG]

I'd guess it would move the max TK to a lower rpm.

nope, it will go higher.

short runners = hp
long runners = torque

 

[billfisher]

14.57 is the exact number it calculates to for 5700 rpm. now that is for max torque rpm. another way to say max torque rpm is horsepower. hp = (torque x rpm)/5252. the actual torque peak should be around 4200. peak cylinder filling at high rpm's is at 5700 rpm's. i really don't want to get back into this thing, do i am going to make total length from intake valve to runner opening to 13". there is another benefit to this, increased plenum volume. it is hard to calculate at this point, but it looks to be 1.5 - 2.0 litres. ford has a history of making it's intakes less than half displacement for torque. aal of that runner volume is useless for power, only plenum volume helps me. also air moves like a stretching rubber band, a long column is hard to start moving, but it has a lot of enegy when it does and pushes itself into the cylinder at low rpms. this short runner setup will let the column get moving quickly. i intend to "bell" the runner openings as much as possible. i can remember an extreme example with 5.0 fuel injection. there is a mainfold with practically no runner length. it MAY help higher, but even F1 intake runners have some length. i wish i could use variable trumpets like F1. they vary the runner length with rpm's.

 

[hotmustang331]

Yea, runner lenght can only do so much...after that its up to the heads and cam and stroke to determine RPM capability.

 

[Black2001GT]

Did you ever figure out how to control the VCT?

 

[mrvax]

Bill, what do you do for a living? You seem to have a mechanical engineering background.

 

[billfisher]

yes

Did you ever figure out how to control the VCT?

i am getting a quote for two 2000hz 1.5a 0-100% duty variable dc drive controllers. they attach with industry standard DIN connectors. they are stand alone small package devices. they orperate on 10-30 vdc. i can use the variable signal from the crank exciter to vary duty. the price ? i will see. it is solved, and i can install them any time. last priority right now. these solenoids are in use in hydraulic control everywhere. they do not require a pulse modulated driver signal, i can use analog dc.

 

[billfisher]

my educational back graound is manufacturing engineering tech. i am not SME certified. in my junior year i dropped out. ten years later i started back and changed my major to computer science. so i have a b.s. in computer science and an a.s. in engineering tech. i had way more than enough credits but i changed because of my schedule. now i am an electrical tech with TVA. i worked as a mechanic and welder for 9 years. i built high performance/race motors there. i have to give all the credit for my mechanical skills to Jeff Bixler. he owns a yellow 70 shaker SCJ dragpak torino. 12.10 from a roll start with 10" slicks.

i was 'confused' about my orientation. he 'educated' me on which make rules. i went to talladega in 85 and watched bill elliot lap the field between yellows. run away from freight trains of chevy's. anyway i am trained an all manner of fabrication. brakes,presses, certified all positions in mig,7010 stick , stainless 609. electronics guru. my family has generations as machinists. i am sure you didn't want to read all of that. i just don't know how to answer short. my nick name is "critical bill", because my answers to questions will put you in critical condition.

my dad has a masters in mechanical engineering. (ret)

 

[mrvax]

Off track but we have similar backgrounds. I am a computer programmer also but used to be an "engineering tech". I never designed electronic circuits but I did troubleshoot & repair them. I enjoy programming a lot better. I spent a year in Millington, Tenn. during the early 80's learning avionics in the Marine Corps. What part of Tenn are you in?

OK, back to project 5.4L 3-valve.

 

[billfisher]

i never was myself working in electricity/electronics when i changed to programming. i interviewed for about 6 jobs in programming and this job. i guess office politics turned me away. this job also started out 20k higher.

 

[DBMSTNG]

i am getting a quote for two 2000hz 1.5a 0-100% duty variable dc drive controllers. they attach with industry standard DIN connectors. they are stand alone small package devices. they orperate on 10-30 vdc. i can use the variable signal from the crank exciter to vary duty. the price ? i will see. it is solved, and i can install them any time. last priority right now. these solenoids are in use in hydraulic control everywhere. they do not require a pulse modulated driver signal, i can use analog dc.

why not get an SCT pro racers package?

 

[billfisher]

what is the point. i can use the reprogramming. but how will it help VCT?
i am not looking to get a 2005 pcm, at least not right now. although i have priced them just in case. i see no reason to do that if i can control it exactly like i want it. dyno tuning(track) will be necessary for exact parameters. for example, do i start the cams at full advance, or a few degrees retarded? what is the best rate of change? at what point retarded am i losing power. i can control all those things electronically myself. i do think it is a good idea to buy it. just for tuning not for VCT.

 

[DBMSTNG]

what is the point. i can use the reprogramming. but how will it help VCT?
i am not looking to get a 2005 pcm, at least not right now. although i have priced them just in case. i see no reason to do that if i can control it exactly like i want it. dyno tuning(track) will be necessary for exact parameters. for example, do i start the cams at full advance, or a few degrees retarded? what is the best rate of change? at what point retarded am i losing power. i can control all those things electronically myself. i do think it is a good idea to buy it. just for tuning not for VCT.

the point is that you can adjust the VCT with the SCT PRP. SCT would give you a base tune to work with that would have values preset for the VCT. you could then adjust them to see what produces the best runs. also, you can have the computer compensate for the change in manifold volume.

 

[Bonez5.4]

Just wondering why you are doing this? Are you going to put it back on the 5.4 3v it came from?

 

[nl mex]

i like this man's ideas....

 

[billfisher]

yes it is going back in it. with a higher rpm band. i will use vct and stepped headers for bottom end.