iron engine core to aluminum?

Ok, so If I have the room, you are recommending that a good engine would be the 02-05 Explorer for a two valve or I can go all the way and try and get a 4V engine from a Lincoln Mark VIII, Marauder, or a Cobra.
Do you know what years of those models that have those engines off the top of your head?

I just want to say that today have been incredible for the amount of relevant info that you guys have been feeding me. I cannot thank you enough...

Since you're already decided against pushrod OHV's, we'll take them off the table.

If you're going to go 2V, then the '02-'05 Ford Explorer/Mercury Mountaineer would be our best choice. PI heads/intake and aluminum block. No other Ford vehicle was equipped with an all aluminum 2V engine. If you do insist on using that F150, engine at the very least ensure it's of the PI head variety. The early non-PI headed engines were dud's as far as performance goes. PI heads and intake were found on Mustang's between '99-'04, Crown Vic's/Mercury Marquis/Lincoln Town Cars after '01. Trucks and Vans from '01-'04 got the heads, but you'll have to source the intake from another vehicle.

If you're going to go 4-Valve, then complete Cobra engines form '96-'01 are the ticket. The '99 & '01 being the more desirable than the '96-'98. An '03-'04 Cobra engine would be ideal, but it uses a cast iron block and supercharger...which aside from adding a considerable amount of power, also add a considerable amount of weight and cost to the overall engine package. If those aren't available, an, '03-'04 Mercury Marauder engine is virtually the same as the '99-'01 Cobra, but has the '03-'04 Cobra heads.

As stated previously, you could go with a Lincoln Mark VIII, Navigator, Aviator, etc 4-Valve engine as well, but take into account that all of these engines will require an upper intake swap for performance consideration. Which again, may, or may not add considerably to the cost depending on how inexpensively you're able to find the swap parts. A turnkey engine is always more desirable and less expensive in the long run IMO.
 
Keep in mind that 4.6 2V's can be made to look very nice if you know what you're doing. The stock PI intake manifold looks terrible, but there are a couple choices such as the Bullitt, Trick Flow, or P-51 manifold that when painted look great. Here's a couple pics of painted 4.6 2V's:

Using the P-51 manifold:

THR_0829_07_016.webp


Using the Bullitt manifold (could also use the Trick Flow and it would look similar):

IMG_1236.webp


I think your project sounds like an awesome idea. It sure would be unique and cool to be able to open the hood and see one of the engine pics I posted above or a 4.6 4V.
 
Those 2V 4.6's look beautiful. The first on though is too tall, I'd need a low profile intake.

How can i tell the difference if I have PI heads or not?

The intake ports look different. The PI heads have a more square appearance, the NPI heads have a teardrop shape to them.

PI heads:

3590d1235953465t-99-pi-heads-p3010421.webp


NPI heads:

pi-install-image-16.jpg


You can also tell by the shape of the intake manifold. On the PI intake manifold the drivers side front runner is in front of the passenger side front runner, while on the NPI intake the passenger side front runner is in front of the drivers side front runner.

PI intake:

PI%20intake.jpg


NPI intake:

Picture17115118.jpg
 
Wow, thanks! that makes it clear. I'm going to keep my fingers crossed until I get home to see if I have the PI heads.
Can I use any intake manifold on my heads as long as it is PI to PI? I will need a lower profile intake then the F-150's which is crazy tall.
 
Wow, thanks! that makes it clear. I'm going to keep my fingers crossed until I get home to see if I have the PI heads.
Can I use any intake manifold on my heads as long as it is PI to PI? I will need a lower profile intake then the F-150's which is crazy tall.

Yeah, and if you're looking for the show car type finish like the engine shots above, I'd look at getting the Trick Flow intake manifold. Summit sells it for around $800 and IIRC it comes in black, silver, or natural finish.
 
I'm not looking for a show type finish be cause that would cost a lot of money. I now have a baby to look after and I want to keep contributing to her college fund and our retirement savings so I can't go all out. I would just find a less tall intake manifold from another car if it is possible.
 
I'm not looking for a show type finish be cause that would cost a lot of money. I now have a baby to look after and I want to keep contributing to her college fund and our retirement savings so I can't go all out. I would just find a less tall intake manifold from another car if it is possible.

Grab up that Explorer engine then. It's got everything you want, on the budget you have to work with.

The 4V's have the greater power potential and those big DOCH heads look nice when you pop the hood....but all that "bling and blam" is going to cost you.
 
Ok, So I will keep my eye out for a 02-05 Explorer engine and dump the F-150. I trust your guys judgment on this. If anybody sees a good deal let me know!!
[email protected]

Does the explorer have a tall intake manifold?? Or, like the F-150, will I have to find something that is shorter and still fits?
 
IIRC the explorer has the same manifold as the Mustang, just a different TP and plenum.

Keep this in mind as well. You can pull the cam covers, front engine cover, and the intake manifold clean them up and paint them with spray paint... would probably look really nice and wouldn't cost very much money :shrug:
 
We have a powder coating set up at my work. It's just used to powder coat some in-house made tools that we use in manufacturing. I just need to get a slightly bigger oven (craigslist??) and maybe I can powder coat the engine block, heads, and valve covers.....
 
We have a powder coating set up at my work. It's just used to powder coat some in-house made tools that we use in manufacturing. I just need to get a slightly bigger oven (craigslist??) and maybe I can powder coat the engine block, heads, and valve covers.....

The cam covers are actually plastic, so regular spray paint would probably work better than powder coat.
 
Does the explorer have a tall intake manifold?? Or, like the F-150, will I have to find something that is shorter and still fits?


IIRC the explorer has the same manifold as the Mustang, just a different TP and plenum.
I believe mechanically, the plenum and throttle body are the same. The differences are purely cosmetic. The Explorer says "4.6L SOHC" on the top of its plenum, where the Mustang has the running pony on the top of its plenum.

Ford Explorer

163_0501_Shootout_07z%2B2004_Ford_Explorer_XLT%2BEngine_View.webp


Ford Mustang

MustangEngine.webp
 
I checked last night.
For what it's worth my F-150 heads are PI.

Then assuming you can live with the iron block, pick yourself up a PI intake manifold and inlet with associated hardware and go to town.

If you're really set on an aluminum block, save yourself the trouble and just pick up an entire Explorer engine from a pick n pull.