99 Cobra built shortblock/holset turbo build

[rockthemullet]

UPDATE:

I was a little worried about the head gaskets that I had in there so I pulled the heads and swapped in some Felpro MLS Blues.

I reassembled everything and turned my attention to the bottom end. I went to throw the oil pump pickup on and this happened...

I had put the extended main studs in the wrong place on the block. DAMN. So I had to swap the studs around and retorque everything. Threw the pickup and the stock windage tray back on.

Cleaned up inside and the oil pan as much as I could and installed the Russell -10AN bulkhead fitting for the oil return.

Here she is before she gets all buttoned up. The timing is all set and its all external from here.

I got the front cover back from my welder, grinded everything to an acceptable finish and painted it with flat black engine paint. I plan on tearing everything back down this winter and making it all nice with powdercoat and ceramic coating but until then, this is what I'm sporting.

The front cover looks a bit different now. I've shaved everything I won't be using. For reference, this is what it looked like already powdercoated but before I decided to shave it. You can still see remnants of some of the webbing near the valve cover on the passenger side. I'll take care of that when it gets taken back off for powdercoating.

So anyway, valve covers are on too. I'm going to clean the intake manifold after work and get that on, along with the motor mounts. At that point, the engine will be ready to go back into the garage for reinstallation. I'll be on to the transmission to get the valvebody figured out and getting those two together for the drop in. Stay tuned!

~Eric

 

[Got9lbs]

Sweet! How long before its all done and on the road

 

[rockthemullet]

Sweet! How long before its all done and on the road

I really don't know in all honesty. I haven't figured out what I'm going to do for a tune and money is the limiting factor right now. I'd like to get it out this year for sure.

 

[rockthemullet]

Progress was made this weekend.

I took the plunge and started on the valvebody conversion...

This is what it looks like under the filter

Here it is under the plate, which I later found out I didn't need to remove (note to self)

After removing the actual valvebody. Some of this stuff needs to be modified. The round piece on the top right needs to be removed and springs replaced. The sensor just below that is replaced with a vacuum modulator (didn't get pics unfortunately).

The actual valvebody. There was a lot of work that went into swapping springs and solenoids. My hands were too dirty to take any of those shots though.

After the conversion. You really can't tell a difference because 99% of the stuff is internal, lol.

Buttoned up and ready to go back in the transmission.

I had a buddy come by with his cherry picker to get the engine out of the house and back into the garage. This was a bit tricky to say the least. We got the engine stand to the rear sliding door but the engine was too wide so the entry had to be modified. The engine was picked up on the rear deck, swung around, and dropped back down on the engine stand off of the deck. It was tricky but took a lot less time than I anticipated.

So that is where we're at now. I need to slightly enlarge the mounting holes in the PA 8 bolt flexplate for the stock converter (glad I checked). From there, the transmission gets mated to the engine and everything will be ready to drop in. I'll have to install the B&M shifter first and a few miscellaneous odds and ends but getting the engine in the car is right around the corner.

Until then, this is what the engine itself looks like all buttoned up. Aside from the turbo kit and wiring harness, this will be just about the only thing in the engine bay since I'm not running accessories.

~Eric

 

[JeffB]

Again, nice work.

 

[Pure84GTT]

very nice work so far !

 

[rockthemullet]

Thanks guys!

BIG UPDATE

I started off by rebuilding the engine and trans harnesses. There are certain features that I won't be using and there are a few things about the routing of the harnesses that really bothers me so I'm doing my best to improve on Ford's work. I finished the trans harness and installed it on the drivetrain before dropping that in. I still have a bit of work to do on the engine harness.

Stock and intact from the dealership.

The main connectors are different (99 manual Cobra/99 automatic GT) so one of the connectors had to be repinned.

I decided to repin the engine harness but it didn't matter either way.

The connector had to be drilled out in certain areas because unutilized areas are now being utilized.

Other wires were pulled from the main connector to be fed to the center console area for manual operation of the lockup and overdrive switches (needed with a manual valvebody).

Next was the shifter. Cobras were never built with automatics so the trans tunnels left no provision for an automatic retrofit. Instead, I had to build an adapter plate to mount the shifter to the tunnel. I could have cut a larger section out of the trans tunnel (the common procedure) and made a much simpler adapter plate to replace the sheetmetal but I've gone out of my way to make sure anything I do to the car can be reversed, so very minimal cutting.

I decided to mount the plate from underneath and it turned out well.

Once the shifter was in, the drivetrain could be dropped in (buddy John in the background).

So that's that. The engine/trans is in. There is still PLENTY to get done but we're on the home stretch. I threw a few things in the bay to get a better idea of where everything will sit. The rest of the turbo kit is with my welder and hopefully I start getting some of that back on Monday. I also need to pick up a bunch of odds and ends and bite the bullet on some injectors. Until then, here are a bunch of pictures to give everyone an idea of what I'm working with. Pics are blurry, I'll try and get better ones later :/

~Eric

 

[Got9lbs]

looking good! I guess I should get a move on finishing my notchback then.

 

[ctgreddy]

that thing looks sick. it's funny how much different and cleaner it looks with that shaved timing cover. mad props to you, can't wait to see it done!

 

[rockthemullet]

looking good! I guess I should get a move on finishing my notchback then.

Haha, no worries... this thing won't be much competition for anyone. I can't drive for the life of me and its just a little 4.6L, ha.

that thing looks sick. it's funny how much different and cleaner it looks with that shaved timing cover. mad props to you, can't wait to see it done!

Thanks a lot, I'm getting excited... its right around the corner! I would say the biggest thing holding me up right now is springing for injectors.

~Eric

 

[rockthemullet]

I got the rest of the hot piping back from my welder. I got it in the bay, cleaned up the turbo a lot and bolted it up. Looks like everything is going in nicely. HOWEVER, I won't be able to run the exhaust like I originally had it set up... it leaves absolutely no room for the cold piping! I tried spinning the compressor housing but its just not going to work the way I want it to. I don't have a choice but to try and route the downpipe under the kmember on the driver's side. The biggest issue with that setup is that I won't be able to run as low as I want to. At least I'm not cutting up the front bumper and I should be able to quiet it down a bit more going this route as well.

~Eric

 

[SuperStang90]

Im a little curious. Why the baby blue compressor housing? :lol:

 

[jtcstrat]

Im a little curious. Why the baby blue compressor housing? :lol:

x2. please tell me thats not staying like that eric

 

[rockthemullet]

It was supposed to be turquoise but it didn't turn out right, lol. Its some model car paint I had sitting around. If the heat kills it, I'll repaint. If it doesn't, that bitch is staying! I think it breaks up the monotony of the engine bay quite nicely, thank you.

~Eric

 

[SuperStang90]

haha, im sure it will burn off. The turbine housing just painted or ceramic coated?

 

[rockthemullet]

haha, im sure it will burn off. The turbine housing just painted or ceramic coated?

Painted with that rustoleum 500* paint. I have my doubts, but we'll see what happens...

 

[dudek]

looking good!
any projected dates for it to hit the road yet?

 

[turbo89gt]

Painted with that rustoleum 500* paint. I have my doubts, but we'll see what happens...

Haha I dont think any paint will last, that baby will get red hot!! Are you gonna keep the wastegate open air, or re route it?

You are doing a great job on this build, everthing is perfect........well, almost.....egghmm blue turbo housing eghhmm......:lol:

 

[SuperStang90]

Painted with that rustoleum 500* paint. I have my doubts, but we'll see what happens...

It will burn off quick lol. Exhaust housings can get in excess of 1600 degrees!

 

[Stang04GT]

Nice looking build