Allright here you go guys, I just copied all the threads again and posted them here.
Sorry about the link above to my thread on stangtuning I just got rid of it.
QUOTE=mark007;8684544]theres no curse, just lack of funds. ive been sitting on my i/c'd kb idea for a year now. it'll work, but im not in a big hurry. once i iron out some small electrical issues, tune it, and drive it i'll get started on the i/c. i just dont want to see her down anymore.[/QUOTE]
Glad to see your still in the IC game you'll get to watch me and learn from my mistakes. Thanks to Mike though who started this thread for making it possible for me. I don't think I would have attempted this without his efforts and some of his pics. I'll post up from his site close ups of his welding on the intake.
Did some work today on the lower lip of the front bumper. I'm gonna try and mount the I/C as low as possible to get max cooling from the opening. I also worked on a block off plate for the intake side of the bypass. I used a sheet of Aluminum and but the piece to size with my radial arm saw and yes no special blade needed a regular carbide blade cuts great if you go slow. I shaped the piece using my metal cutting blade on my chop saw. A little sanding with 600 grit then hit it with my polishing wheel and looks great.
Here is where I clearanced the inside of the front bumper cover to clear the 3" pipe.
Last night the KB came off in preparation for the fabrication and welding work. I seperated the 2 pieces and cleaned the gasket gunk off. I was very surprised how light those 2 pieces are, its the blower case and drive that are hefty. I started openning up at the end of the discharge manifold by first drawing my my lines 1 1/4 by 3 1/4 of material inside to come out. The bottom lip that mates to the blower case I left 1/4 in and the top is opened to the roof of the intake. I also went deep into the sides where the bolt holes are and cut out almost all of the extra material around the bolt hole. I'm not worried as these bolts don't see much torque and some sealer there will stop any leaks. I used my drill to puncture about 20 holes around the perimeter and then a medal blade on my elec jig saw. Finished up the hole with air tools and carbide bit for aluminum. Looks real nice and should be big enough opening to support the 3 inch pipe. So my plans to cut part of the top out as shown in my mock up plans is on hold. I'll try and get some pics up soon, wife went on business and stole the camers :-(
Did some more porting and opening up the discharge end this morning. The bolts going through really choked it out again so I took out more on the roof section. Also cut out the solid chunk in the middle section and smoothed it out should flow very nice now.
Worked on the discharge today, used my small jig saw again with a metal blade. Found out that it cuts much better with WD-40, otherwise the blade clogs up. Smoothed it out with carbide cutting burr. Welder is coming over today to take a look at the job so I'm hoping the Pipe will be in by Thursday and I can get started cutting and shapping the ends to be welded on the intakes.
Very nice got the Intercooler and 2.75 inch pipe kit today and I must say CXracing has great deal The value for $$$ is there. The intercooler is huge I can't believe it looked like a 4". Its 31x12x3 very nice and polished the pipe is as ordered polished with rolled lip. Silicone couplers are 3 ply and clamps are high qaulity staneless and heavey duty. Got the IC intalled and bolted in fits very nice. I will have to trim more of the mouth ends to fit the pipe and coupler in.
Got the 3" pipe kit today from CXracing. I was very pleased with how well things went. I mostly worked on the drivers side I started at the IC with a 90 deg L and then went with another 90 L up towards the top of the fender panel. Lucky I orders and S bend, because it fit perfect and made the turn out the fender hole where the windshield tank use to go. I had a 45 degree silicone to join the S bend and the 90 L, fit perfect. I then spent about 2 1/2 hours cutting hammering and bending and shapping the small piece from the KB manifold end to the S pipe. It fits great and should look good. I used a U pipe from the passenger side IC to just inside the frame rail. I'll finish that up tomorrow. Here are some pics of my progress.
Got the front cover chin lip and new air deflector bolted down today. When I bolted it down to the lower rad support it pulled the front covers lower lip down about a 1/2 more so even more of the intercooler will get a direct shot of cool air. The rad and fan should went in no problem, so now I'm just waiting for the welding which should be done Sat and then another day to assemble the manifolds to the compressor case. One dry time and then I'll bolt it down and prepare for smaller pullies:-)
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Today, 06:26 AM #23
roh92cp
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Vehicle: 92 Ford Mustang
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I was a little dissapointed I didn't get the intakes back from the welder today. Oh well I made good use of my time polishing my kB compressor and snout and some of the pipe. The mothers ball really does a hell of a job. I did have to use my high speed buffer with some cutter on some deeper scratches, but it should look really nice when I get back together. I'll be sure to take some nice pics.
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Today, 06:26 AM #24
roh92cp
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Well here is my meth injection plan for my intercooler setup. Talked with Rodney at AIS about injecting meth through the compressor and then the intercooler and he said it was fine and would cause no harm to the intercooler. He suggested 9gph before the compressor through the intercooler and then maybe 5gph after the intercooler going to the discharge. I can't imaging I will have anymore heat issues after this and I hope to see some good power gains with the added boost and timming.
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Today, 06:27 AM #25
roh92cp
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Worked on the bypass system today. Had to start from scratch there as The 3" inlet on the discharge took the place of the bypass. I used the same flange that led back to intake side, but cut it off, flipped it around and then angled it to fit next to the 3" pipe. Very close fit but it worked once welded up looks almost stock. The bypass itself is gonna be mounted on the side of the pipe that comes vertical from the side of the engine. It was the only place that had room to mount it. I baught a flange of ebay 1 1/2 inch ID and then cut a hole in the pipe and cut angles in the flange. Off to the welder with that.
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Today, 06:28 AM #26
roh92cp
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Vehicle: 92 Ford Mustang
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Yesss....got the manifolds back from the welder and I must say I'm impressed, it looks awsome. He even polsihed all the welds and did the intakes too...wow what a guy, and all for $88. I did some more porting on the inside of the drivers side pipe where its welded to the intake from the inside just to smooth things out. There will be plenty flow through the transition from the round 3" pipe to the rectangler end of the manifold. Raising the roof of the at the end of the manifold really did it. The manifolds are all assembled to the compressor and everything fit back together nice. I'll let the gasket material dry over night and mount the KB tomorrow. The bypass bung and pipe are at the welders and should be done by tomorrow. I'll have to run to Napa and see if I can find a 1 1/2" heater hose with the proper bends to get my bypass system up and running. Then its time to fire up the beast
The KB is installed and got the bypass pipe this morning from the welder. On start up it revs to about 3 grand and then cuts out, did this like 10 times. I checked everything, looked for vac leaks or unplugged sensors and found nothing. I tried holding the throttle open a bit and was able to get it run at 3 then 2k for 3 minutes then slowly let the throttle down until it finally idled. I Let it warm up and then went for a short ride. First observation was the KB's wine now is much louder, must be due to the thinner pipe comming off the manifold is resonating the sound out throught the pipe and intercooler. Sounds really sweat now, love that KB wine. The car runs well at cruise and responds well to light throttle jabs, very responsive, no stumble or hesitation. Now if I let off the throttle and coast it will sometimes stall. I'm gonna try resetting the idle and check TPS volts. I'll let you know. Its funny now it starts no problem no more high reving and cutting out. I have to burn out my old winter gas before I romp on it. I was able to get some cruise and light throttle data. Outside temp today is 52 degress, 4th gear cruise at 2500rpm showed ACT temps of 70 degress. So 19 degress above ambient, so far the intercooler really looks like its working well. I'm very happy with the results sor far. Even more interesting was how fast the ACT temps change now. When I crack the throttle open the air temp immediatly goes down, and i was only going to @ 20% throttle so I can imagine full throttle will result in even lower ACT. Stay tuned because I'm just getting strarted, havn't even tried the meth yet. :-)
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Still have not run inot boost yet, burning off winter gas first. Throttle feels real crisp though and cruise temps were 70 deg yesterday with ambient temps of 52. So this mother is really cooling well. Last year I was seeing intake temps of 180 at cruise. I don't know my power level, no dynos around here. I'm looking at running 14psi with dual nozzle meth injection soon. One injector before the blower through the intercooler and one after intercooler. Block beware I can see 500 rwhp is just around the corner.
OMG.....Its fast now. I put on the 2.5" pulley today and it ran like a rapped ape. I saw 13 psi from my data logs and the best thing is ACT temps were 63 degrees, 10 degrees above ambient. I only lost 1.5 psi through the intercooler from last year running 14.5 with the same pulley. The difference is huge feels like a different car. Its never pulled so hard anywhere in 3rd gear it will smoke the tires and go sideways. 4th gear is on the verge of breaking loose now, and I haven't even run meth or extra, timing 17* total now. The blower wine is very noticable now anytime under load. I really can't believe how fast this car is now. Like I said last year I ran the 14.5 psi with meth and it was not even close to what the 13 psi intercooled feels like. This is what I was hoping for, and I got all of it and more. Can't wait to get the meth nozzle in and try some timming now.
I also re did my bypass valve tubing with some 1.5 in plumbing pipe and new silicone elbow, Loks good now.
I got all the meth nozzles in today 6gph before the screws in the back of the flowzilla, and 9gph in the 3 inch pipe just before the discharge. I fabricated the bund today from an incert off the intercooler kit. I cut it in half, shaped it for the pipe radius then tapped it for threads. I also tried my hand at a new product for welding aluminum, called Durafix Dura Fix Aluminum Welding Aluminum Brazing Aluminum Soldering & Repair Rod it really works well and I was able to sand it and polish the welds. The nice thing abou the Durafix is the welding rods melt into aluminum, kinda like brazing at 735 degrees. So you can use propane or MAP gas with a benzomatic burner tip. I can't wait to try it out and get some hard data. Its gonna rain for 5 days here.
This is the bung I welded in with DuraFix rods and the propane torch
Ok guys, I said I would do a DIY and build list thread for my Fox body KB A2A project. I had most of this on another thread but this is step by step. I hope this thread helps other fox owners to find and search for this idea.
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