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

[sonicmach1]

For a change of pace, I have just finished upgrading my electrical wiring for the battery, alternator and grounds. I had high RPM voltage drop with a couple alternators, different pulleys, and with 2 AWG positive wiring to the alternator. Coupled with that is my big stereo and sub upgrade project drawing more power. So the battery terminals were messy.

My Build Level

Two crimpers - one hydraulic press tool and one mechanical
Used tinned copper heavy duty marine lugs
Used marine grade adhesive shrink wrap
1/0 AWG wiring for alternator positive and ground
1/0 AWG from battery to distribution box
2 AWG ground wires
MAXI fuses with 6 AWG terminals
200 Amp circuit breaker for alternator positive line
100 Amp MEGA fuse for sub amp in a marine rated fuse holder​

Hydraulic Crimper



I found several issues with the wiring:

1. Importance of good grounds. For a car never driven in the rain, no salt, etc., with 22,000 miles, the grounds were in poor shape.

Stock engine block to frame
Completely rusted underside of engine block nut.
Self tapping screw (!) used on other end to attach to frame


NEW

 

[Brandon Adams]

For a change of pace, I have just finished upgrading my electrical wiring for the battery, alternator and grounds. I had high RPM voltage drop with a couple alternators, different pulleys, and with 2 AWG positive wiring to the alternator. Coupled with that is my big stereo and sub upgrade project drawing more power. So the battery terminals were messy.

My Build Level

Two crimpers - one hydraulic press tool and one mechanical
Used tinned copper heavy duty marine lugs
Used marine grade adhesive shrink wrap
1/0 AWG wiring for alternator positive and ground
1/0 AWG from battery to distribution box
2 AWG ground wires
MAXI fuses with 6 AWG terminals
200 Amp circuit breaker for alternator positive line
100 Amp MEGA fuse for sub amp in a marine rated fuse holder​

Hydraulic Crimper
View attachment 92036


I found several issues with the wiring:

1. Importance of good grounds. For a car never driven in the rain, no salt, etc., with 22,000 miles, the grounds were in poor shape.

Stock engine block to frame
Completely rusted underside of engine block nut.
Self tapping screw (!) used on other end to attach to frame
View attachment 92032 View attachment 92034

NEW
View attachment 92031
View attachment 92033

Damn. I have 88K. I should definitely take a look and replace mine


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[sonicmach1]

I checked my engine boss ground for my airfuel meter too. It was also pretty rusted having been installed in 2009. I sanded the boss, used a new ring terminal, and added a new 2 AWG ground to a chassis frame bolt as well.



I then coated all the ground mounting locations with my POR-15 rust proof paint.

 

[Brandon Adams]

Did Ford techs teach you all of this?


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[sonicmach1]

Ha! No. Just an OCD Mechanical Engineer by trade!

 

[Brandon Adams]

Ha! No. Just an OCD Mechanical Engineer by trade!

Hope to be me more like you one day!


Sent from my iPhone using the svtperformance.com mobile app

 

[sonicmach1]

Here is the overall plan I used for my system after I completed all the work.

 

[sonicmach1]

Here are some miscellaneous info on the electrical project:

I removed the extension post from the alternator and bolted my 1/0 lug with one nut connection.

I added a bolt to the alternator case for the 1/0 lug for the ground to the battery

I use a circuit breaker versus fuse for the alternator charge line - less line losses.

All wire is SGX cable or better. All copper - not copper clad aluminum.

I went at least 2 gauges larger than needed.

I looked around for some time to find the best clamps. I found these MIL spec ones - solid, 3/8" bolt, heavy duty for $23 per pair. I wanted to stay away from the set screw type stereo terminals.

 

[sonicmach1]

I initially bought some high quality cables on Amazon - Spartan Power brand for reasonable prices. I supplemented that with my custom length cabling using my crimper and lugs.

I was able to replace these fuses


With direct wired MAXI fuse holders ($12 on Amazon with a fuse)

For longer wire leads, I took apart the crimp and added my own wire section (to avoid another butt connection).

Almost done


Now I just have to remove that battery sticker! It is a new battery.

 

[03 DSG Snake]

Polished my new Borla exhaust end sections that I bought back in 2009.

View attachment 92014

Preparing to put the Ford Racing Diff cover on. What a big difference versus the stock cap! View attachment 92015 View attachment 92016 View attachment 92017

Does it look like it offers much if any extra fluid capacity?

 

[Brandon Adams]

So much fluid capacity obviously. But how more more did you gain vs studs did you gain over bolts on the cover.

 

[sonicmach1]

Does it look like it offers much if any extra fluid capacity?

From my research, it seems like the stock level is about right. It will vent if you put more than ~1.5 qts. Also by looking at the cover shape, the new one may be a bit less.

 

[Brandon Adams]

Can't wait to see your car on the road

 

[whitedevil95]

Great work! I always get nervous doing wiring stuff like that. Its where im least knowledgeable.

 

[sonicmach1]

Making progress!
I got the cradle on the trans jack, the diff is in, all new bolts. Home stretch now - pop in the halfshafts, bolt on the spindles, toe links, sway bar. Then bolt the subassembly to the car.

 

[sonicmach1]

IRS is assembled. Tomorrow is the big reinstall day!

 

[Sonic605hp]

Now I want an oatmeal creme pie so bad! I haven't had one in years!!

Studding the diff cover. Tapped the holes a bit deeper ~ 4 more threads. I may keep this setup or revert to the new allen head bolts supplied with the cover.

View attachment 92018 View attachment 92019 View attachment 92020

 

[sonicmach1]

Now I want an oatmeal creme pie so bad! I haven't had one in years!!

Ha - LOL! Yes those were an impulse buy at Menards. I haven't had them in almost 25 years.

 

[sonicmach1]

Finally another few hours to get the IRS frame back in and stuff bolted. The end is in sight now!

 

[CobraBob]

You're just about there.....completion! Man, you've put a lot of time and parts into your project, but the results speak for themselves. Well done sir. Well done!