dohc aluminum block swap

mustbereel · May 11, 2007

I normally hang out in classic tech but I just bought an engine, T56 and IRS unit from a 2003 Cobra which I intend to put into a 67 coupe project. The engine only has about 31k miles on it so it should be fairly fresh. One big drawback for this swap is the weight of the DOHC engine. I am considering buying the FRRP 4.6L Aluminum block for supercharger. Can I essentially swap all of the parts from the iron block to the aluminum block? I would of course install new bearings and rings while I am at it.

I also assume there would be some machining required before the block is ready for assembly. Has anyone done this swap?

Uncle Meat · May 11, 2007

I think if the new block has knock sensor bosses they'll have to be ground down so the intercooler will fit.

U.M.

mustbereel · May 11, 2007

bosses

Ford has taken care of the bosses on this particular block.
Per the FRPP site:

M-6010-A46SC

Latest generation aluminum 4.6L block
Features chilled bulkhead casting process for a stronger main web and bulkheads
Round main web windows reduce stress areas for potential failure
Ball burnished 17mm-thick main caps for strength and rigidity
Machined for 2003-2004 Cobra front dress, will also fit some 2-valve front dress from iron 4.6L blocks
Knock sensor mounting bosses eliminated for use with supercharger applications

Uncle Meat · May 11, 2007

mustbereel said:
Ford has taken care of the bosses on this particular block.
Per the FRPP site:

M-6010-A46SC

Latest generation aluminum 4.6L block
Features chilled bulkhead casting process for a stronger main web and bulkheads
Round main web windows reduce stress areas for potential failure
Ball burnished 17mm-thick main caps for strength and rigidity
Machined for 2003-2004 Cobra front dress, will also fit some 2-valve front dress from iron 4.6L blocks
Knock sensor mounting bosses eliminated for use with supercharger applications

SWEET! Sounds like that block is the hot ticket for your build then!

U.M.

P.S. Since you will be swapping everything over to the new block go ahead and replace the pistons while you're at it. They are the weak link in the reciprocating assembly. Get a good set of CP or Diamond pistons.

mustbereel · May 11, 2007

bore

If I get new pistons, is there any reason I shouldn't go with a 3.7" bore?

Uncle Meat · May 11, 2007

mustbereel said:
If I get new pistons, is there any reason I shouldn't go with a 3.7" bore?

Well you know the old saying..... There's no replacement for displacement!

U.M.

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