1BAD96SVT's build thread - 11/11 forged motor

95PGTTech

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1BAD96SVT's build thread - 01/08 wiring/engine reinstall

We don't really have a dedicated forum for build-ups/projects but I'm frankly getting tired of the high-school-drama-zero-tech-info-nothing-but-post-whoring sn95forums.com so here goes. Some tech, some mutimedia, some dry humor.

Mike, 1BAD96SVT, contacted me some time ago about installing a forged long block into his 1996 Cobra after symptoms leading him to believe he had hurt the stock motor. After seeing my own builds and other customers I have done, he felt that it was time to just get it done (the car had been stored for some time, angry at it). If the name doesn't ring a bell, I don't think anyone on this forum doesn't recognize this car...

ccwcobra235.jpg


After discussing a few options, I persuaded him to buy the parts and assembly through a shop I have been working with for a few years, Lorenzo's Fast Flow & Cylinder Head. He trailered the car down to me 10/25 and made the deposit with the engine builder. His friend was very surprised to see that they had brought it to an Acura dealership. I owe a big thank you to my service manager Steve P. and owners the Davis family for their no-holds-barred side work policies, more than a dozen fast Mustangs have been built between these doors with a few STis and EVOs (and even a T/A...) sprinkled in between...without their generosity I would still be working in my driveway and two car garage in the cold on my side stuff.

Anyway, test drive, warm motor, compression test revealed low pressure cylinder 7, really low cylinder 8. I didn't want to just assume blue smoke sometimes at idle and real bad (CROPDUSTER bad) on decel after boost meant motor hurt, sometimes it's a little BS thing like a PCV system set up wrong. For leakdown, 7 and 8 were terrible and I could really hear it through the oil fill cap. Either hurt pistons or rings, almost 500rwhp on a stock B head motor tends to do that. I informed the customer of the diagnosis and began tear down the next day.

Sorry for some of the terrible pictures. I take my 450D to shoots, races, and meets but keep a simple point and shoot in my tool box for when my hands are dirty.

Put the car on the lift backward to have more room when the motor comes out.
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Just the start of the many piles of parts.
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Blower, exhaust, etc.
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Upper intake, started the harness.
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Trans. With the tools I have at my disposal, it's really no more difficult to pull it in the car rather than drop engine and trans together and then separate. I really recommend doing it this way if you have shorties.
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What is this mess?
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Oh, this will never do either (see HID ballast).
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Here's one you guys can help me on. Vac valve located in p/s front of engine bay, may have been relocated. One connector two wire. Manifold vacuum to it, output is capped. Car has had SAI deleted.
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My OCD is beginning to show. Guess what I don't like about this picture?
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We will no longer need these ugly, ineffective, and purposeless emissions components.
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More OCD, apparently also turret's...
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I wasn't going to make fun of Mike for double side taping his KB BAS to the engine bay, but he made a thread about it, LOL. You threw yourself under the bus on that one, bud.
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http://www.svtperformance.com/forums/how-278/654159-how-kb-boost-spark-install.html


Getting there...
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Ugliness. Car is COP swapped, so I recommended we find a C head P/S bracket. We later did.
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Just one example of something I started doing a few builds ago. Instead of writing lots of crap down, just take pictures as notes. When you see the pics when you upload them, you'll remember to tie up "loose ends." Questions you need to answer like what is this, where does this go, nuts/bolts that were missing, stuff that needs to be addressed, etc. This one was "I found a damaged/broken wire."
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Dear Mike: thanks for powdercoating, painting, and chroming EVERYTHING in your engine bay. It looks great at car shows, and makes your car builder crap his pants in fear of scratching things. Like your valve covers. Not a lot of clearance on either side, we'll pull both before removing the engine.
100_4658.jpg



Gotta have the fender covers. Keep in mind they are magnetic, so keep the undersides clean - any dirt/small metal gets stuck on the magnet and dragged across the paint like 60grit sandpaper, the exact opposite your intentions of a fender cover.
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A couple hours in wrapping it up for the night.
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Glass trans out. Need degrease bad.
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More junk out.
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Steeda X2 balljoints. Does this look correct (spacing between bottom of spindle and taper of BJ)? Never used them before.
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Stupid P/S lines are last.
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BAM!
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Disassembled, took some pics of timing cover as studs are pretty annoying to remember which go where. Now lots and lots of piles of parts.
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Tossed longblock in back of Escape. 10 hours of work, not the quickest I've ever done but worked at a pretty comfortable pace and had no issues.
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New front spring lower "insulators." :D
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Wrapped it up, boxed the parts and pushed the car outside, awaiting motor builder now.
 
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95PGTTech

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Lorenzo says two weeks. Manley rods, Manley pistons + .020" (9.0:1 static), Manley NexTec valve springs. Chock full of stock Ford gaskets and ARP head studs. Blueprinted and the nine yards runs just shy of 6000. In the mean time, my OCD runs loose...


Car has no washer fluid tank, so that makes this pretty useless. Bye bye. I broke a washer nozzle.
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Cleaned Dynamat off MGW greatness. Not fun times.
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Pavement v. silicone...looks like pavement wins. I could slap a new one on...or completely redo the intercooler piping for more ground clearance.
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I find a new-to-me front bumper pull method leaving the header panel and headlights on it...very happy I am, Mustang (esp. SN95) headlight hardware ALWAYS breaks.
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A few stock bolts were missing and replaced with aftermarket ones. OCD much? No problem, I have a couple hundred pounds (pathetically...that's very literal) of stock Mustang bolts!
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Girdle was leaking. Drop. Check tooth pattern. Check backlash (.006", nice). Cookie off. Reseal. Let it sit a few days with no fluid in it, really helps it set up.
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Hope I took that blue rag out. I'll know if I have noises on the first test drive. :D


Intercooler looks funny in front opening, and many couplers are kinked. Damn radiator support in the way...
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Better...
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Measure and mark crash beam for "clearancing."
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HIDs will be mounted in my signature location, no more zip tied in engine bay. This ain't no Honda! :D
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More piping/coupler kinked due to restrictions in space available...more on this later.
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P/S fog light bounces around, missing the spring!
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Super rare radiator shroud with the headlight panels still in tact...one anyway. The only thing better than blue painter's tape is black duct tape!
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Old bolts from UPR radiator shroud panel need to go! Find some stock bolts!
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These should help power production with 15psi!
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Who wants to buy? $100 picked up (just the pipe, sensors obviously going back on car)
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Intercooler was really bothering me how it was mounted. Having the bottom end tank featured in the small bumper opening is not a power-producing idea. And it looks like a gangbanger trying to show off a mouth full of chrome. :D
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Tape up rad support. Mount bumper. Shine light through opening. Trace shadow. BAM! Opening transferred onto rad support. (Only took me like 35 times bumper on/off moving I/C around to figure this out...)
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I/C test fitting to have fins on opening, intercooler centered on opening, and level. Yes, it is held up with a few pieces of mechanics wire and duct tape. Yes, I just did get done making fun of gang bangers and then duct taped an intercooler to the front of the car. And posted it on the internet. Where the customer could see. I'm a ****ing genius, aren't I? I also dropped it twice, good thing Procharger builds these things strong. Or we use really soft concrete.
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Crash beam on looking pretty decent.
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Remember my OCD? I could have just eyeballed it, but I had to measure it left/right to determine exact center. Then use two laser levels to make sure it was perfectly level. The areas left over blue painters tape need to be sprayed black.
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Making new upper mount crash beam to I/C. Drilled hole for easy front access.
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Mounted solidly for the first time. So far, everyone has commented looks way more bad ass with the fins showing, car looks serious. Also one view from about five feet away from an average person's six foot height or so shows the PROCHARGER lettering on the end tanks.
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Escape makes good transport.
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Built reinforcement for upper I/C mount.
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Welded HID ballast mounts.
100_4791.jpg
 
Last edited:

95PGTTech

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P/S bracket arrives.
100_4774.jpg



polished 98 rails. BBK regulator. autometer gauge.
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Every Mustang rusts here. No worries, caught it early.
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More stuff arrives.
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BoneHead Performance powdercoated timing cover to match the charge pipes. Not too shabby for $40, dropped more stuff off to them.
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Remember that KB BAS? Some six layers of duct tape makes a really good vibration dampener, then tuck it away where it won't be seen. Run dial into cabin to eventually end up in glove box.
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Repair engine harness (was previously tied into this, no good).
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Install it on body harness side. Depin connector, solder. Examples of old soldering job shown. Not a hot enough soldering iron used, me thinks. Now all good and tucked away where no one will ever see.
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Ditched the charcoal dump tube.
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Wrapped up the SAI pump wiring.
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Viper alarm connections twisted together, doh!
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Way cleaner engine bay ditching/moving stuff!
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Leak?
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Trunk switch. Must remember to fix.
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Where did all the driver side stuff that was in the engine bay go? :D
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This car is a 96 so it was subject to the recall/cooling TSB. I'll have to check the fan against my old one.
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Obviously a lot more pics of the two weeks since pulling the engine in a day. Working fast then not taking too many pics, now just milking the job while waiting for the engine back cleaning up little things here and there. I push it inside every night so I mind as well put a few hours in here and there. Prevent some issues down the road and tidy the car up for the customer, he does show it. Was supposed to have the motor back today, something was on back order or whatever so now we're told the earliest we will have it back is Wed the 10th. I'll take a lot more pics going back in will be slower due to everything being powdercoated or painted or chromed gotta be really careful and slow.

We're swapping to 8 rib and a 10% lower, it has a 3.40 upper on it now making 13.5lbs I think he said. Adding long tubes and dr. gas x pipe. I think Mike said he was at 497 or something before. I personally think this blower is maxed out as far as power goes, I'd like to pick up more mid range with the stronger engine and longtubes/lower but don't expect really any much more on the top end (D1SC). No, he did not sell the wheels, I requested he not bring the car with the CCW SP500's. The car sits outside the dealer all day and I'd frankly like to not be responsible for that kind of $$$ tied up into them. Rain/attention/etc. He's bringing them a few days before picking it up to get aligned (dropped K member) so I'll grab some 450D pics then.

Also, picked up this beauty.
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Set it up on a lift arm across the shop. Really impressed with it so far, I did the take picture every X seconds feature and set to 10 seconds. Took like 800 some shots over four hours I worked on it today. Viewed the photos on my PC and it was like a time lapse thing when you scrolled really fast, cool to watch. Sad to see how much BSing I do and how little work I get done, LOL. Maybe I'll play with the video once the car is running, Mike requested I put some break in miles on this puppy to make sure there are no early issues.

A keen eye will notice the discharge for the I/C (upper passenger side corner).
Hold onto your feathers!

Update 11/6:

Largely still just fooling around killing time until motor is here. Put another two hours or so into the car.

2 quarts of 80/90 and 4 ounces of friction modifier went into the rear. Pretty damn exciting stuff, I know. God damn isn't that easier than laying on my back in my driveway with a hand pump and this junk going EVERYWHERE...not leaking yet.
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A more detailed pic showing where the HIDs are mounted on the back of the crash beam.
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Used my "put light in object trace shadow" method of transferring gaps/openings again, worked great.
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Simplified the HID wiring, these aren't needed.
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Hacked the hell out of the crash beam to completely uncover the I/C. I actually calculated wrong and took an inch too far in each direction off, I wanted the cut lines to line up with the welds on the I/C. I have another crazy idea (speaking of re-doing fab work...) that if I have time with later I may play around with. Gotta chop up the foam piece next to match.
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Unnecessary weight. You're fired.
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Finished tidying up the wiring on the driver side. Moved Viper alarm, ground source, power wire, hood ajar switch, and audio system master power wires into driver side fender well, much cleaner.
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Some eye candy for today - no word from the engine builder, but BoneHead Performance finished these up! Check them out, free plug for a nice kid and his dad running a really legit, clean shop.

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UPDATE 11/14:

Got some more done this weekend just killing time really, the weekend was ended by running out of C-25. The motor was due 11/5, then delayed to 11/10. Now I am told "sometime next week." Damn Lorenzo, you do great work, but you sure drag shit out.

Been trying to figure out a way to get the powerboost lines that need replacing to look a little better. I came up with this steel wool/flat black setup. Any opinions?
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You know nothing good is happening when this is the view under the car :lol1: Got to work making the new lower intercooler mounts.
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How it worked in my head was take some 1/2" all thread, weld to radiator support, use torch to bend the front part straight, install.
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Unfortunately, my dumb ass fully welded a test fit instead of tacking it like I should have and found out that moved the intercooler a good inch up from where I wanted it. So chop the all thread and reweld it where I needed it. UGLY!
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Solution! Should provide some pretty decent ground protection too.
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Not too shabby.
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Finished up welding the other one. My welding can still use some work, good thing I'm handy with a grinder.
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The intercooler now hangs from just the bottom mounts for the first time (this is important in terms of now the crash beam can be installed or uninstalled separately from the intercooler).
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A keen eye would spot the other progress in that photo, at left. Remember how the intercooler outlet pointed right at that crash beam mount? This is where I ran out of gas, so I hit it with some paint quick to keep it from rusting. I plan on replacing it with a single piece that is both intercooler pipe and crash beam mount.
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In case you are wondering, the now lightened crash beam has no problem just mounting with just the right (driver side) mount.
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How does the honeycomb delete look? Any opinions keep it or ditch it?
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Also replaced that UPR hardware to look more normal.
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Tried bolting my 98 fan/radiator in as this 96 never had the recall performed. WTF, they are completely different sizes. Being that the bottom mounts are the radiator support itself, are you going to tell me 96-98 Cobras have different radiator supports? The upper mounts are evidently different too.
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Last edited:

95PGTTech

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Also, thanks Mike for helping me win employee of the month!
The owner was talking to the service writer today asking who should win it for October and he said "the Mustang guy."
LOL. $100 AMEX card and my face on the suck up of the month plaque to throw darts at.
Maybe I'll take the old lady out for dinner...










...or waste it on car parts like I do all my other dimes...
 
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svtrickey

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Looks, great. When can I bring mine up to you? No one I have found in FL takes this much attention to detail.
 

95PGTTech

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Looks, great. When can I bring mine up to you? No one I have found in FL takes this much attention to detail.

Any time you want (609) 558 - 1649.
I'm not the cheapest initial estimate in the world but pretty damn competitive and my customers always leave with a lot more than they came for. If I give a quote I stick to it and I try and be as timely as humanly possible. I just try to treat everyone's car like my own.

FWIW, you would be the third farthest person to trailer something to me. I don't know if anyone is going to beat a Denver customer.
 

Iso

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Awesome build thread, It's good to see someone have so much attention to detail on such a nice cobra
 

98 svt

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Wow man, great job. I shoulda had you do the work on MY car. maybe I would've had it back by now.
 

95PGTTech

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Wow man, great job. I shoulda had you do the work on MY car. maybe I would've had it back by now.

never too late to pick the car up on a trailier and have it finished up the right way. probably less expensive too than waiting for it to come back (hopefully headache free).
 

PSUCOBRA96

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your nice and close to me and you do the kind of things an owner would do, I like people who are like me, picky on the details. My problem is I am picky on the details, but dont always have the skills to do it the best way. Nice work.
 

95PGTTech

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your nice and close to me and you do the kind of things an owner would do, I like people who are like me, picky on the details. My problem is I am picky on the details, but dont always have the skills to do it the best way. Nice work.

99.9% of the car stuff I've learned through the years, and absolutely all of the fabrication, has been by seeing other guys do stuff in person or online and just jumping in, often without the skills or the tools. You buy more tools along the way, and if you're willing to fabricate something, rip it apart, redo it, rip it apart, redo it, rip it apart, redo it, etc. until it's perfect you'll develop a lot of new skills and tricks. This is partly why my junk never gets done...every single little thing I do on a customer's car I try to incorporate into mine, then find even new ways of doing stuff, so I end up re-doing what I've already done 35 times. Next time you want to try something, jump in. What's the worst that can happen? Make sure you have a reliable DD.

I wish I could bring mine to you!!!

Where there is a will, there is a way. For those who don't own truck/trailer, UHAUL is very reasonable on truck rental and 2 wheel dolly or full trailer rental, your preference. I also do transport.


Update 11/6:

Largely still just fooling around killing time until motor is here. Put another two hours or so into the car.

2 quarts of 80/90 and 4 ounces of friction modifier went into the rear. Pretty damn exciting stuff, I know. God damn isn't that easier than laying on my back in my driveway with a hand pump and this junk going EVERYWHERE...not leaking yet.
100_4813.jpg

100_4815.jpg

100_4816.jpg


A more detailed pic showing where the HIDs are mounted on the back of the crash beam.
100_4822.jpg

100_4823.jpg


Used my "put light in object trace shadow" method of transferring gaps/openings again, worked great.
100_4825.jpg

100_4827.jpg

100_4828.jpg


Simplified the HID wiring, these aren't needed.
100_4820.jpg



Hacked the hell out of the crash beam to completely uncover the I/C. I actually calculated wrong and took an inch too far in each direction off, I wanted the cut lines to line up with the welds on the I/C. I have another crazy idea (speaking of re-doing fab work...) that if I have time with later I may play around with. Gotta chop up the foam piece next to match.
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Unnecessary weight. You're fired.
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Finished tidying up the wiring on the driver side. Moved Viper alarm, ground source, power wire, hood ajar switch, and audio system master power wires into driver side fender well, much cleaner.
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Added this update to initial posts for first time viewers.
 

Glueyes1

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Damn man that's awesome,i love how you pay attention to every little detail...I have spent a ton of money in so many different shops only to be disappointed by there workmanship..I will seriously look you up next time..
 

Bufgt281

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(96 Cobra Build

Damn man that's awesome,i love how you pay attention to every little detail...I have spent a ton of money in so many different shops only to be disappointed by there workmanship..I will seriously look you up next time..

X10 This guy does a graet job.Over the top on his attention to detail...
 

mcaligiuri

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very nice, that car is soo nice. i think he should of went with an h pipe though. i have the longtubes with h pipe and 40 flows, get compliments on it all the time.
 

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