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1996 Mustang (SN95) ---> 2.3t swap
#11

My current goal is to get the engine permanently mounted in the car. Then, I'll mount the intercooler, A/C condensor, and radiator. As you've seen, I have plenty of room for all of it Smile .

Here is the motor plate I've modeled:

http://i53.photobucket.com/albums/g69/96...bly001.jpg

Here is a picture of the actual engine:

http://i53.photobucket.com/albums/g69/96...ign001.jpg

Finally, this photo shows the clearance for the thickness of the motor plate (0.25").

http://i53.photobucket.com/albums/g69/96...ign002.jpg

I am not sure how well the water pump is going to work with the impeller partially covered by the motor plate. If the car doesn't stay cool, I have two options:

1) Go to an external water pump, redo the motor plate without the hole for the water pump, and weld a couple fittings to the spot that used to be occupied by the water pump.

2) The water pump has plenty of thickness. I believe the mounting flange could easily be milled 0.25". In essence, this would put the water pump's mounting depth back to its OEM position.

Jon, give me a call to discuss the T-coupe.

Have a good day!
Michael
1996 Ford Mustang
2.5t Folvo w/ HE351VE, MS3X, & TKO500

1958 Plymouth Savoy
Flathead 6 and 3-on-the-tree

2018 Audi RS3
2.5t, AWD
11.23 @ 121 mph
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#12

Is that a solidworks model of a 2.3 block??

If so, did you make it? If not, where did you get it? If it's up for grabs I'd like a copy, if not, that's cool.
1962 Falcon
MII Front Suspension, 4-Link Rear, 8.8, 5.0 V8 (Formerly 2.3T )

88 Ranger 2wd RB20DET (Formerly 2.3T, sold)
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#13

It looks like you are going to have to make clearance for the timing tensioner in the motor plate.
Looking for another TF.
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#14

Quote:Originally posted by Methos:
It looks like you are going to have to make clearance for the timing tensioner in the motor plate.
Ya, I might have to clearance it a little bit, but it won't be a big deal.

Yesterday, I modified the used intercooler I purchased:

Here is how I received it (inlet/outlet on same side):
http://i53.photobucket.com/albums/g69/96...ods001.jpg

Here is how I modified it (outlet moved to opposite side):
http://i53.photobucket.com/albums/g69/96...ods002.jpg

http://i53.photobucket.com/albums/g69/96...ods003.jpg

http://i53.photobucket.com/albums/g69/96...ods004.jpg

My TIG welding skills are getting better, but I still need a LOT of practice Smile .

Today, I ordered some 0.25" thick x 8.0" wide x 36" long 6061 aluminum for the motor plate. I also ordered a 3-1/8" hole saw for the water pump hole.

Also, I got my turbo today. It's a HE351VE off a 2009 Dodge Cummins diesel. At first glance, it appears to be in good condition.

NeonGreen: PM me your email address and I'll send you the file.

Have a good day!
Michael
1996 Ford Mustang
2.5t Folvo w/ HE351VE, MS3X, & TKO500

1958 Plymouth Savoy
Flathead 6 and 3-on-the-tree

2018 Audi RS3
2.5t, AWD
11.23 @ 121 mph
Reply
#15

how will the ve turbo work? and whst type welder and settings did you use
many Fords, just no time...
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#16

Quote:Originally posted by 23reasons:
how will the ve turbo work? and whst type welder and settings did you use
On the HE351VE turbo, I will ditch the electronics and use a wastegate actuator to move the turbo between two 'extremes'. With this setup, I will be able to set the low and high sides.

I have two welders -- one is a Lincoln MIG welder and the other is a Thermal Arc 185 (a/c TIG, d/c TIG, and stick).

Have a good day!
Michael
1996 Ford Mustang
2.5t Folvo w/ HE351VE, MS3X, & TKO500

1958 Plymouth Savoy
Flathead 6 and 3-on-the-tree

2018 Audi RS3
2.5t, AWD
11.23 @ 121 mph
Reply
#17

A couple updates...

HE351VE Turbo:
Firstly, here are a couple pictures of the turbo. To remove the turbine housing, I used a torch to heat it up. Then, tapped it up with a brass hammer. While working it off, I constantly verified the impeller spun freely to make sure the housing wasn't binding on it.

Turbo (as received):

http://i53.photobucket.com/albums/g69/96...rbo002.jpg

This photo shows the electronics removed from the turbo. I will mount a wastegate actuator to the lever arms (visible) to move the turbo between the two extremes. One extreme will spool the turbo quick while the other extreme will minimize exhaust back pressure.

http://i53.photobucket.com/albums/g69/96...rbo003.jpg

Upper Radiator Support:
With the BBF in the car, clearance between the radiator fan and water pump was minimal. To gain some much needed clearance, I cut the upper and lower radiator supports out of the car of moved the radiator towards the front of the car over 5". The downside of that was I had to remove the hood latch and it would have required hood pins.

To keep a more stock appearing car (no hood pins), I used some angle iron to make a new upper radiator support. Then, I bolted the hood latch back to it so every thing functions in an OEM style.

I notched the angle iron to help it follow the contours of the car. Then, I tack welded the 'high' spots before using a hammer to persuaded the angle iron to follow the curves of the car.

http://i53.photobucket.com/albums/g69/96...ort001.jpg

Finished product:

http://i53.photobucket.com/albums/g69/96...ort003.jpg

Intercooler:
I bought a used vertical flow PTK intercooler. I've decided to mount it horizontally. I will use an air scoop to force air through at. I have ordered some parts from McMaster Carr that will simplify the mounting setup.

http://i53.photobucket.com/albums/g69/96...cooler.jpg

Motor Plate:
I bought 6061 aluminum with for the motor plate. It's dimensions are 0.25" x 8.0" x 36". For the water pump hole, I bought a 3.125" (3-1/8") hole saw.

The aluminum metal with the water pump gasket and hole saw sitting on top of it.

http://i53.photobucket.com/albums/g69/96...ate001.jpg

Water pump hole drilled:

http://i53.photobucket.com/albums/g69/96...ate003.jpg

Bottom view of plate with w/p shows the impeller:

http://i53.photobucket.com/albums/g69/96...ate005.jpg

http://i53.photobucket.com/albums/g69/96...ate006.jpg

I need my poly trans mount before getting the motor plate in the car. It should be here this week. I am going to push the engine to the driver's side of the car. Because of the manual brakes and manual steering (no p/s pump), I have plenty of room to move it over. This will increase the room for the down pipe to exit the engine bay.

Have a good day!
Michael
1996 Ford Mustang
2.5t Folvo w/ HE351VE, MS3X, & TKO500

1958 Plymouth Savoy
Flathead 6 and 3-on-the-tree

2018 Audi RS3
2.5t, AWD
11.23 @ 121 mph
Reply
#18

:thumbup: Nice job!
87 XR4ti, 88 turbo Mustang,86'Mustang,94' GT,95' GT- sons cars.
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#19

Another update...

Motor Plate:
I made the motor plate today. Though I'm happy with how it turned out (for the most part), I'm going to remake it. I have concerns about the strength of the plate above the counter-balance shaft. Currently, it is ~3" thick there. I am going to buy another piece of aluminum and 'shift' the 'template' down on it. This will shift the motor plate upwards and give me additional thickness in that area.

http://i53.photobucket.com/albums/g69/96...ate001.jpg

http://i53.photobucket.com/albums/g69/96...ate002.jpg

http://i53.photobucket.com/albums/g69/96...ate003.jpg

http://i53.photobucket.com/albums/g69/96...ate005.jpg

The timing belt tensioner clears the motor plate by ~0.020". Everything else has plenty of clearance.

http://i53.photobucket.com/albums/g69/96...ate006.jpg

Intercooler:
I decided to mount the intercooler horizontally. I welded four aluminum tabs to the the intercooler. Then, I used weld tabs to mount the intercooler to the 1.625" (1-5/8") tubing that I have for my bumper support and radiator cross member.

Intercooler Tabs:

http://i53.photobucket.com/albums/g69/96...ler001.jpg

Intercooler Mounted:

http://i53.photobucket.com/albums/g69/96...ler002.jpg


Tomorrow, I plan to rotate the upper intake and get my new pedal assembly in the car (swapping to a manual transmission).

Have a good day!
Michael
1996 Ford Mustang
2.5t Folvo w/ HE351VE, MS3X, & TKO500

1958 Plymouth Savoy
Flathead 6 and 3-on-the-tree

2018 Audi RS3
2.5t, AWD
11.23 @ 121 mph
Reply
#20

I can't wait to see how this turns out. Looks like a great project.

Are you going to use any type of scoop to direct air through the intercooler?
Ron Gibson

'83 Thunderbird Turbo Coupe
'84 Mustang GT Turbo
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