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1986 TC Project

What's that saying?  Take one step forward and 2 steps back.  I mounted the fuel rail and upper manifold today and started to transfer over my 65 mm throttle body adapter which was made several years ago by David Godfey. Turns out that I forgot that the stock upper had to be port matched to 94/95 65mm Mustang throttle body adapter plate.  The bores do not line up as it currently stands.  I need to pull the upper intake off so that I can port match it to the adapter plate.  

I also forgot that I need to purchase (1) stock throttle body gasket and (1) 65 mm throttle body gasket and some new hardware as the countersunk screws are too long and the allen key screws are rounded out. Looks like this will take another couple of weeks.

Have  a Happy New Year all!

   

   

   
400HP or Bust!
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It's starting to come together.  I port matched the adapter plate to the upper intake using a carbide router bit and blended to back side of the flange.  I picked up a sheet of MR Gasket and made new gaskets for the throttle body assembly.  Installed the upper manifold, throttle body & accelerator cable. Just need to finish up the fuel, vacuum lines, intercooler piping and re-install the alternator.  I may need to reroute the valve cover breather to a second catch can which would be located on the passenger side fender.  Its starting to get tight between the manifold and fire wall. Hoping to go through the pre-start check list and start it up tomorrow.

   


   
400HP or Bust!
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You may have already purchased replacements for those "rounded-hole" flat-head Allen bolts, Anthony ~ BUT - if not - the Torx-head versions are FAR  less-likely to become "tool-damaged" (LINK). [Image: confused0024.gif]
Placerville, California
(former)  2.3T '78 Courier ~ (current)  2.3T '87 Ranger & '82 Mazda B2200 (smog-exempt diseasel truck)
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(01-04-2020, 11:34 PM)TurboRay Wrote:  .
You may have already purchased replacements for those "rounded-hole" flat-head Allen bolts, Anthony ~ BUT - if not - the Torx-head versions are FAR  less-likely to become "tool-damaged" (LINK). [Image: confused0024.gif]

Thanks for the suggestion. I am going to pick these up.  In the mean time, I did purchase new hardware to continue with the mock-up.
400HP or Bust!
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Got it done today.  Finished mounting up the new manifold. It was a real PITA.  Had to modify several more items to make it work; dip stick mount, fuel lines/fittings, vacuum lines, etc...It took several attempts to get everything to work together.  I just need to set the base fuel pressure and figure out a breather for the valve cover.  

I primed the motor several times to check for fuel leaks then started it up.  One thing that I noticed is a heck of a lot of intake noise coming from the upper manifold.  If I put my hand on the upper while running the noise goes away.  I might add a piece of duct liner.  I will try and shoot some video and get it on the dyno to see if this has been worth the effort.

   
400HP or Bust!
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(01-12-2020, 10:16 PM)tcoupeturbo Wrote:  .....a heck of a lot of intake noise coming from the upper manifold.   
 
Obviously, the noise won't impact performance, Anthony ~ BUT.....if it's sufficiently annoying, you might consider getting some black self-adhesive high-density sound deadener to adhere onto the large surfaces, altho it might detract from the clean looks, lol.

FWIW ~ I see you have the large "slow-down" Essy w/pump pulley and maybe(?) the companion undersized crank pulley? Those pullies were designed primarily for mini-stock racers that were continually running above 6K rpm. BUT......if you're using the car primarily as a DD on the street,  I suggest close monitoring of the engine temp - since those pullies drastically reduce the coolant flow in low-rpm (street) operation, especially with OEM &/or generic parts-store w/pumps. My 2¢...... [Image: confused0024.gif]
Placerville, California
(former)  2.3T '78 Courier ~ (current)  2.3T '87 Ranger & '82 Mazda B2200 (smog-exempt diseasel truck)
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I set the base fuel pressure today, 42psi with vacuum line disconnected. She is running real good. Here is a short video.  You can clearly hear the intake noise. 


https://youtu.be/DRute_jamj4
400HP or Bust!
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Had some favorable weather today so I thought it would be a good day to take the car out for a ride. I just put in 5 Gallons of Sunoco 260GT about a week ago. Went to start it and it ran for a few minutes then died. Gauge is registering low fuel pressure, 20 psi. Fuel gauge is showing empty. I was initially thinking that the sending unit failed. But the low fuel pressure makes me think I have a leak somewhere.

I put 2 gallons of super in it and put the key into the on position, I hear the pump and the fuel pressure rose to 40 psi. I go under the car and see fuel pissing from one of the lines. I turned the ignition key off. This stinks. It’s the 2nd time this year that the fuel line sprung a leak. Maybe after 35 years it’s time to replace the lines... I was planing on this just not as soon. I need to figure out how to eliminate the push lock fittings from the fuel sending unit. It would be easy if this was a Mustang tank as several companies already make fuel sending units with AN fittings.

The plan is to upgrade the 255lph pump to aeromotive 340lph and upsize the lines maybe -8 on the supply and -6 on the return. Plan is to have the option to run E85. Any thoughts?
400HP or Bust!
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You may need larger than a 340lph pump for E85 as that pump would be 5% smaller than what you currently have (it's 25% larger but e85 requires 30% more fuel flow at the same power).

You can brace fittings on to the stock sending unit if necessary.

I've honestly never heard of anyone having leaks like this so with the push lock stuff and plastic lines. Is it leaking at the o-ring inside the fitting or did you replace the fitting and it's leaking between fitting and line or what?
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