All Small Six Intake Port Divider with 2 Barrel Conversion

This relates to all small sixes

NickC

New member
Hello FordSix,

I finally finished my winter project: a custom-made intake port divider and 2-barrel conversion.

The engine is a 1978 large log 200ci installed in my 1964 Ford Falcon Futura (3-speed automatic). I video recorded timed acceleration tests and repeated them under three different configurations:
  1. 2-barrel carburetor with 2:1 barrel conversion
  2. Super Sniper 2300 EFI with 2:1 barrel conversion
  3. Custom intake port divider with 2-barrel conversion
Configurations 1 and 2 were very similar, with no statistically meaningful horsepower difference. However, the Sniper completely solved my vapor lock issues and makes cold starts effortless, even after sitting for weeks. I would recommend the Sniper 2300 for drivability, though it does lose a bit of the 1960s charm.

My only complaint about the EFI is that the touchscreen is somewhat sensitive and tends to jump around due to dust and debris. My Falcon is a convertible, so it is exposed.

According to my analysis (with ChatGPT assisting in calculations), the intake port divider combined with the 2-barrel conversion resulted in an estimated 9.16% average increase in net traction horsepower.

I used the “Physics Toolbox” app for GPS and elevation measurements. The video frame rate was approximately 0.033 seconds per frame (30 fps), which limits timing precision somewhat. The Physics Toolbox app logs at 1 Hz, which is not ideal for high-resolution acceleration analysis.

The test road was approximately a 3% uphill grade, and speeds were limited to about 70 mph. The Falcon retains its original 1964 3-speed automatic.

Interestingly, the calculated net traction horsepower gain was more pronounced at higher RPM rather than lower RPM. Given measurement limitations, there is some margin of error, but the improvement appears consistent.

Subjectively, drivability is noticeably smoother and more responsive. It is definitely quicker — though not quite Mach-E GT quick.

I am very happy with the conversion.

Enjoy the photos.

Other notes: Compression and leak down tests before the top-end rebuild were adequate so I did not resurface the valves, head, or block. I did replace the valves, head bolts, thermostat, and leaking valve seals, but not the keepers or springs. I performed a mild polishing of the ports. I power washed and glass bead blasted the head rather than a more appropriate and typical approach.
 
Here are the images :)

I machined the log head as shown and used a little JBWeld to backfill the driver side rear of the racetrack machined surface. There was ~1-2 mm of solid material left, but I wanted more for the gasket. I sealed the gasket only to the head side. The four hex bolts used to secure the divider were measured and spaced appropriately so they do not interfere with the gas flow. The divider is removable from the box and is angled about 15 degs off perpendicular to direct some gas flow to the first adjacent intake runners.

And for fun, I machined part of the symbol for entropy onto the box, symbolizing "Control Entropy".
 

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Good job (y)
I do not think that that gasket maker is rated for gasoline/alcohol, but I could be wrong. keep an eye open any leaks down the road.
 
THE BOX ! = excellent simple in form concept', followed through to it's function.
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the 'Box' solves a couple of dimensional problems, simplest one being the box raises larger carb/FI flange level to clear valve cover . ( placing fuel bowls away from headers ). Smaller footprint on intake runner makes it simpler . Also the use of pontoon fastening to the manifold allows simpler intake sealing without fastener complication . I'll take one !.
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I use 2X1 adapters and currently also working out a 2Bbl conversion. With angle grinder milling , I opened a D0xx head for experiment. The runner sides where sealing required, is supplemented with epoxy. With limited resources , I had a "concept of a plan" to weld C-channel back to back with required @ 3degree wedge for a 'box'. - ( all look like nails if you only have a hammer) The pontoon fastener bosses of the 'box' may be best new idea I've seen. A forum member helped create file for 'printed' wedged 2bbl adapter but haven't found suitable material.
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. . . . . . . .

Permatex 'Ultra Black RTV' claims to be "Oil Resistant" but only "Motoseal' and similar claims to be "Fuel Resistant" AFAIK . Regular RTV not good , a quality epoxy has worked.
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Mr. Gasket Weber/Holley converter riser has minimal sealing at fastener bolts, the fastener wells can be epoxy filled for better confidence.

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have fun
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Very nicely done! Without the means to machine my own box, I created a redneck version by stacking phenolic spacers. I like the looks of yours better than what essentially looks like stacks of wood on mine! LoL
 
Hello FordSix,

I finally finished my winter project: a custom-made intake port divider and 2-barrel conversion.

The engine is a 1978 large log 200ci installed in my 1964 Ford Falcon Futura (3-speed automatic). I video recorded timed acceleration tests and repeated them under three different configurations:
  1. 2-barrel carburetor with 2:1 barrel conversion
  2. Super Sniper 2300 EFI with 2:1 barrel conversion
  3. Custom intake port divider with 2-barrel conversion
Configurations 1 and 2 were very similar, with no statistically meaningful horsepower difference. However, the Sniper completely solved my vapor lock issues and makes cold starts effortless, even after sitting for weeks. I would recommend the Sniper 2300 for drivability, though it does lose a bit of the 1960s charm.

My only complaint about the EFI is that the touchscreen is somewhat sensitive and tends to jump around due to dust and debris. My Falcon is a convertible, so it is exposed.

According to my analysis (with ChatGPT assisting in calculations), the intake port divider combined with the 2-barrel conversion resulted in an estimated 9.16% average increase in net traction horsepower.

I used the “Physics Toolbox” app for GPS and elevation measurements. The video frame rate was approximately 0.033 seconds per frame (30 fps), which limits timing precision somewhat. The Physics Toolbox app logs at 1 Hz, which is not ideal for high-resolution acceleration analysis.

The test road was approximately a 3% uphill grade, and speeds were limited to about 70 mph. The Falcon retains its original 1964 3-speed automatic.

Interestingly, the calculated net traction horsepower gain was more pronounced at higher RPM rather than lower RPM. Given measurement limitations, there is some margin of error, but the improvement appears consistent.

Subjectively, drivability is noticeably smoother and more responsive. It is definitely quicker — though not quite Mach-E GT quick.

I am very happy with the conversion.

Enjoy the photos.

Other notes: Compression and leak down tests before the top-end rebuild were adequate so I did not resurface the valves, head, or block. I did replace the valves, head bolts, thermostat, and leaking valve seals, but not the keepers or springs. I performed a mild polishing of the ports. I power washed and glass bead blasted the head rather than a more appropriate and typical approach.
Great project with a detailed description! Did you settle on configuration 1? Which 2-barrel carb did you use?
 
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