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Cam covers, AFCO, KB 2.2, 03 Cobra Installation Pictures - Some assembly req.!

Discussion in 'Pics and Videos Buffet' started by sonicmach1, Dec 22, 2009.

  1. sonicmach1

    sonicmach1 Active Member Established Member

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    More to come...
     
  2. sonicmach1

    sonicmach1 Active Member Established Member

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    This is my post front suspension project - 3.2L Mammoth liquid cooled:

    KB_Mammoth_Kit_Unboxing1_MAIN KIT_4022018 (2).jpg KB_Mammoth_Kit_Unboxing2_ALL Support Parts (2).jpg KB_Mammoth_Kit_Unboxing2_ALL Support Parts (1).jpg KB_Mammoth_Kit_Unboxing1_4022018 (21).jpg KB_Mammoth_Kit_Unboxing1_4022018 (10).jpg KB_Mammoth_Kit_Unboxing1_4022018 (5).jpg

    KB_Mammoth_Kit_Unboxing1_4022018 (16).jpg KB_Rotors_4092018 (4).jpg
     
    Last edited: Apr 20, 2018
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  3. sonicmach1

    sonicmach1 Active Member Established Member

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    I have already taken the blower apart in order to powder coat the discharge plate, bypass tubes, inlet plenum, t-body adapter and pre t-body intake tube.

    Powder Color Options_KB (7).jpg Powder Color Options_KB (1).jpg

    Powder Color Options_KB (8).jpg Powder Color Options_KB (10).jpg
     
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  4. sonicmach1

    sonicmach1 Active Member Established Member

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    And so the crossmember replacement finally begins.

    Also getting installed are:
    Maximum Motorsports A-arms, end links, bump steer kit, coil overs, and bushings
    OEM engine mounts, wheel hubs, Ford mini starter


    IMG_20180602_185101.jpg IMG_20180602_183733.jpg IMG_20180604_222832.jpg

    IMG_20180604_223012.jpg IMG_20180604_222854.jpg
     
    Last edited: Jun 5, 2018
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  5. 05satinGT

    05satinGT Tire Smoking Specialist Established Member

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    Looks outstanding. I've been viewing this thread ever since it first started. One of my favorite builds on SVTP. Attention to detail is unreal.
     
  6. Sonic605hp

    Sonic605hp Resident Prick. Established Member

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    I want your car if you ever sell, outstanding.
     
  7. Samsred04gt

    Samsred04gt Not Banned Established Member

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    I second that
     
  8. sonicmach1

    sonicmach1 Active Member Established Member

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    Thanks for the compliments. I enjoy doing the work as much as sharing it with others.

    If I tried to sell it, I would never get the value out of it!

     
  9. sonicmach1

    sonicmach1 Active Member Established Member

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    More prep work.

    Painting the new engine mounts high temp black.

    IMG_20180605_200546.jpg

    Cleaning the front hub and spindles. I will be painting them and installing new hubs.
    (I would love to powder coat these too, but our local shop is backed up with work.)

    IMG_20180604_223030.jpg IMG_20180604_223024.jpg
     
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  10. sonicmach1

    sonicmach1 Active Member Established Member

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    Details...Details...

    Baking the high temp paint on the new engine mounts.

    Engine_Mounts_Painting_Baking_6082018.jpg

    Front Spindle Cleaning - Prep for painting
    Hubs are being replaced with new parts

    Old_Front_Hub and Spindle1_6092018.jpg Old_Front_Hub and Spindle3_6092018.jpg Old_Front_Hub and Spindle4_6092018.jpg

    Old_Front_Hub and Spindle5_6092018.jpg

    Spindle After the Metal Zinc Prep
    Ignore the spindle shaft look - It will be polished with 3000 grit wet sandpaper before I put the hub back on.

    Front_Spindle_Cleaning3_6092018_Close.jpg

    Next up - painting the spindles.
     
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  11. sonicmach1

    sonicmach1 Active Member Established Member

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    I coated the spindles and center brake rotors in the black POR-15. Another POR-15 coat tonight then an aluminum color topcoat for the rotors and a black for the brake centers. (You cannot leave POR-15 without a topcoat as it reacts with UV)

    POR_Spindles_6112018 (2).jpg POR_Spindles_6112018 (1).jpg POR15_Disc_Hubs_61102018 (1).jpg

    Brake Rotor Before
    IMG_20180611_215541.jpg
     
  12. sonicmach1

    sonicmach1 Active Member Established Member

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    Final POR15 Topcoat in Cast Aluminum

    IMG_20180613_214906sm.jpg

    New Bolts, Nuts, Washers! All class 10.9, Zinc Coated


    New Front Suspension_Crossmember_Hardware_20180615.jpg
     
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  13. merkyworks

    merkyworks Well-Known Member Established Member

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    Your attention to detail is amazing. Love following this thread, please keep the updates coming.
     
  14. SVT_Troy

    SVT_Troy Well-Known Member Established Member

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    Awesome build coverage! I love attention to detail and corroded parts also drives me bonkers!


    Sent from my iPhone using svtperformance.com
     
  15. sonicmach1

    sonicmach1 Active Member Established Member

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  16. sonicmach1

    sonicmach1 Active Member Established Member

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    Update. 95F and 105+ Heat index. Not a fun weekend to be out in the garage.

    The crossmember is out. Pretty easy to drop it after you support the trans and engine correctly.
    The new one looks much nicer. I will get weight measurements for both soon.

    Stock_vs_Steeda_Front_Crossmember_6172018 (7).jpg

    Stock_vs_Steeda_Front_Crossmember_6172018 (4).jpg

    Motor mounts getting removed and new OEM ones reinstalled.
    I will of course sand off any ground boss areas and will probably do some POR15 painting on any rust areas.

    Heads = -DA version on the driver's side.

    Manifolds
    Are those little stock manifolds just asking to be replaced by headers?! It has been awhile since I looked at a 4.6L 4V engine out of a car, but those are smaller than I expected.

    I could go ahead an order some long tubes and adapter to my catback exhaust for the extra $$$ and extra downtime. Not sure I want to bust a stud and have it down for more of the summer though.


    Engine_Mounts_6172018 (2).jpg . . Stock_Headers_Small_6182018 (2).jpg

    More to come soon.
     
    Last edited: Jun 17, 2018
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  17. sonicmach1

    sonicmach1 Active Member Established Member

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    More detail work.

    Cleaning and Painting the Engine Mounts and Heat Shields
    Wire wheeled, metal etched, primed, and painted
    Engine_Mounts_Painted_6232018 (6).jpg Engine_Mounts_Painted_6232018 (4).jpg

    Cleaning and Painting the Engine Block (After vs. Before)
    EngineBlock_Painted_6232018 (1).jpg EngineBlock_PrePaint_6232018 (2).jpg

    Stock vs. New Ford Racing Mini Starter
    124 oz vs. 103 oz.

    New_Old_Starter_6232018 (3).jpg New_Starter2_6232018.jpg
     
    Last edited: Jun 24, 2018
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  18. offroadkarter

    offroadkarter Professional S***poster Established Member

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    I've been meaning to pick up one of those mini starters for the red marauder at some point, figure it wouldn't hurt replacing the original starter before it goes out.

    Also, in regards to the manifold studs, when I swapped a 130k mile Aviator engine into the black marauder, that engine came from western Pennsylvania and was covered in salt. The manifolds and studs were WAY more rusted than yours and I got every single one out without breaking any. I used a liberal amount of heat on the stud before putting a wrench on it and they all came out no problem.

    It's worth trying, your car really needs LT's if you're going to put a 3.2L kenne bell on there.
     
  19. sonicmach1

    sonicmach1 Active Member Established Member

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    Thanks for the reply! Yes I have no worries about removing the manifolds.
    I think I'm going ahead with the stock manifolds for now. I'd order the ARH ones then have to polish or ceramic coat, then ..... And it will be 2 more months.
    It was not hard to remove the crossmember thanks to my lift so maybe this winter (when I'll install the 3.2L) or next year after some drive time.
    I have to do the clutch anyway!

    I just found out I need neck surgery (fun) so I want to get this driveable soon.

    Take care.
     
  20. sonicmach1

    sonicmach1 Active Member Established Member

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    Well more updates - assembly time now.

    I got a good deal on a set of Magnaflow shorty headers, 1-3/4" tubes, with ceramic coating. They probably are not much different in power vs. the stock log manifolds, but they look nice and probably sound a little different.

    I need to do a port overlay and see how the tubular circle ports compare with the oval (D-shaped) stock ports. So I am not sure if I will keep them or go back to stock.

    On the plus side, the header nuts came loose with very little wrench force! I was shocked by how easily they unbolted. Low mileage, no rain driving really paid off there.

    Magnaflow_Tubular_Headers_6282018 (8).jpg Magnaflow_Tubular_Headers_6282018 (3).jpg Magnaflow_Tubular_Headers_6282018 (6).jpg
    Stock_Exhaust_-Headers_6282018 (1).jpg Stock_Exhaust_-Headers_6282018 (3).jpg Stock_Head_Ports_6282018.jpg

    I have my last order of new fasteners to use now too.
    NewBolts_6282018.jpg
     

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