Turbo 240 or 300

Got the outer edge of the flange pretty much milled to completion. Only a couple spots right next to bolt holes that need a quarter of an inch or so taken off. Also completed the aluminium template.....well kinda it matches the head perfectly right now. So we still need to take .045 of an inch off around all exhaust ports to allow for the tubing to match the head perfectly. Does anyone have the capability to press one off the mandrel bends into a rectangle, to match the T-4 flange. We have pressed a straight piece into a rectangle. But due to the tightness of everything it would be a lot cleaner and nicer if it went right into a bend out of the turbo instead of, turbo half inch straight piece welded seam mandrel bend. I've talked to one guy that says he can do it but I'm guessing I annoyed him with all my questions, and no actual purchase of his skills.....yet lol. Basically he isn't returning my calls any more. He is a custom header guy in Sacramento. I only need two of these rectangles pressed into the ends of two 90° mandrels to go with my twin scroll flange. I have the bends and am willing to ship them to pretty much anywhere. Or I still need some more 2 inch bends so I could have burns send them right to you. I am willing to pay $$$$$ obviously. Otherwise I'm going ghetto extra seam.

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Does a 1996 f-150 have a 58 tooth gear mounted to the balancer? If not i think I'm going to have to make a custom one. Unless someone knows of one that will bolt to a 300 balance, and is low profile. I only have about half an inch to spare on the front of the balancer?
 
Ramian17":mvvw0ew4 said:
Does a 1996 f-150 have a 58 tooth gear mounted to the balancer? If not i think I'm going to have to make a custom one. Unless someone knows of one that will bolt to a 300 balance, and is low profile. I only have about half an inch to spare on the front of the balancer?
The 1996 engine decodes the PIP signal from distributor for sequential injection.
 
Ramian17":1zlmqs3q said:
That's what I thought then why does Napa sell a 96 f-150 crank sensor lol?
Because the 1996 F150 with a 5.0 and 5.8 V8 uses the crank sensor.
 
Super close to finishing the header flange. Milling the finishing touches tomorrow. Once that is done we will finally be playing with the 321 SS!!! I hope you like my plan. Cause I already ordered them. I talked to a lot of intercooler guys and they said it was a good idea. I ordered two of these.
https://www.speedyracer.com/180SX-200SX ... -S15-300ZX search=Universal%20intercooler
And am going to weld them together connect the tanks on one side by turning them into one tank. That way I'll have the inlet and outlet on the same side which I'm pretty sure is going to fit the best for me. What do ya think good idea? I also ordered some silicone fittings and some aluminium piping. Getting closer!!!
 
We actually started on the stainless tubing today. We got one runner from cylinder 6 tacked together, that holds the rear collector where it might actually work fingers crossed lol. I forgot to take pics but will soon. This is what we are going for. It's hard to draw in three D so work with me.
https://www.dropbox.com/s/59mggcrqmcotr ... 8.jpg?dl=0
We aren't very far but it's looking like if we go under the floor and outside the dog house to go around the motor mount, that it will be a build in place piece haha​. Unless we break it in the middle somewhere like in the drawing. My question is does it matter where other than for ease of installation, and what kind of connection.? V clamps, flanges with a heavy seal that are bolted together?
 
I've always had good luck with "V" flanges. I don't like having to deal with seals.
Break it where you need to. No problem.
Glad to see progress.
 
Awesome I will go with the v claps then thanks for the opinion. Oh boy hold on tight. The rear three runners and collector might actually be tacked in place!!!!!
https://www.dropbox.com/s/cewofepxpwlx1 ... 3.jpg?dl=0
https://www.dropbox.com/s/jag3u9eerrs8d ... 8.jpg?dl=0
Gonna start the front three tomorrow and then on to the two inch. We are going to drop the two inch down under the motor mount and out of the dog house before it goes forward and too the turbo. We thought this would be better for heat inside the dog house and. Inside the van. It is going to make the two inch pipes considerable longer. That shouldnt be an issue correct? As long as they are the same length?
 
As I predicted today we redid most of yesterday. We found out right away that the intake didn't fit so well with the front and rear runners in that last header design lol. Now we have this.
https://www.dropbox.com/s/vqgli0qym0f39 ... 0.jpg?dl=0
https://www.dropbox.com/s/0256wsugaw24l ... 1.jpg?dl=0
https://www.dropbox.com/s/5mgnj0900kgfr ... 3.jpg?dl=0
What do ya think. We mocked up the front collector to try to figure out where the two inch is going to be right after the collectors and next to the engine mount. I won't lie it's only a solid half inch from the motor edge. It is the lip with the oil pan seal. Unless someone ... objects? We are going with it. Gonna start the front three banks tomorrow which are going to be way more complicated.
 
I wondered if the previous design left enough room for the intake. From what I can see I think this looks good. Are you taking each of these tubes apart to weld them out individually and then weld the assembly together at the end? I’m not sure how you’ll get to some of those seams otherwise. I don’t remember if you said in a previous post - are you wrapping these when you’re done or having them coated? If so, I don’t think I’d worry about the clearance. Nice work and it looks like fun!
 
Thanks yeah it has been a lot of fun. We will be have to basically​ dismantle the whole thing to get to all the seems. I was going to ceramic coat them. But was wondering if the double slip joints from burns can be coated? I'm guessing not? Should I wrap the joints and the rest of the header after it's coated?
 
Thanks pmuller they are almost all the same length except for cylinder number three obviously. He's our ugly duckling. You still confident this thing is going to make lots of low end torque lol ?!?!?
 
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