Hey Kirkyg.. Look what i found..
Here is your email..From 12/03
Hey man i posted on the 5.4L DOHC thread that is eons long
. I'm looking into the 5.4L Swap in my 2002 GT 5 speed right now. I have plenty of questions that i think are not clearly answered yet by reading the entire thread so Id like to explain what my plans are and see what you think...and if you have any suggestions.
What i want to put together:
- I want to buy a Navigator 5.4L to go in my mustang (where's the cheapest place?)
- Plan to take a 2.2L Kenne Bell kit and mount it on top of the 5.4L
- Will use a custom intake (not sure from where yet but i know modular performance is working on a lower intake for roots/works/kb blowers as we speak and should be out sometime next year)
- Would like to run my t-3650 atleast for a little while (maybe before installing the blower and then swap to a T-56)
Id like to build the 5.4L navigator motor and have it very reliable. I plan to only spin it to 6500 MAX...as i want to avoid alot of the problems you have had (stuff breaking down everywhere). The reason i say this is...i understand how engines work and i've done some minor mods to my vehicle but im not an engineer or a mechanic. I will have a buddy of mine helping me do the swap and he is great at this stuff. Between us i think the majority of the stuff can be handled (besides custom exhaust work).
I want to run the new engine without the blower for a little while (probably more for money reasons than anything but also to make sure its all running smooth as glass before supercharging and going all out). I want the engine to be setup to run 8.4-8.5:1 compression (supercharger...) & put out about 350 hp / 350-360/torque before the supercharger and then who knows with the autorotor on top
. Again this is with a lower redline than your engine (for reliability reasons). I also would like it to fit under a cobra R hood if at all possible. I really hate cowl hoods with a passion and I assume this will require a tubular K-member at a minimum.
Here are some questions/concerns i have that i can't find clear answers to yet:
-Will cobra valve covers fit on Nav. DOHC heads and are they cheap/easy to get? (i think they look sexy
)
- With plans for a lower intake with a KB mounted on top will i need a lower K-memeber for deck height reasons?
- I think this has been answered but just want to have it clarified again...With my GT wiring harness and computer all i need to do is hook in all the sensors (they are all in the say basic setup even though i have an SOHC engine right now...) and have it custom tuned right?
- What lbs injectors would be suggested to work with the KB setup...will it be a problem if i use kenne bell's boost a pump instead of changing fuel systems at first?
- What cams should i get...i want some lope at idle...i've seen you suggest using stock cams with a supercharger but again I really would like a small lope at idle (after all its as much about tough sounding as it is speed).
- Which brings up my next question. If you do an exhaust setup with cobra manifolds or custom long tubes, and flowmasters it should have the same beautiful sound as a DOHC cobra right? As long as it doesn't sound like crap like the triton engines do (i assume because they are y-piped and have a different firing order?)
- What exhaust modifications are necessary. I remember you mentioning if you use a stock 01? 03? cobra exhaust manifolds you can just shafe a little off the flange and bolt it up right?
- What changes need to be made to the a/c mounting & alternator?
- I read that you had serious problems with the stock ford oil system which caused engine failure in your case. I woudl like to avoid this problem but also avoid spending an additiona grand just on the oil system. Do you think the stock setup would be fine for a DOHC setup for only 6500 redline or lower? I really dont want to push the engine to 7500 rpms or anything near that.
What suggestions do you have for internals...what brand rods etc. What things should i do to safeguard from having to pull the engine apart and fix things?
Thanks so much for reading this email. Take your time responding if you need to and any help you can give me will be much appreciated. I'm in a parts compilation phase right now. Thanks in advance!
Kirk Kornegay
So how's the project...?
I can't find my response, But..Here's my response today..And is probably pretty close to my response to this email....
.There is no existing blower manifold to put a KB on a 4v 5.4. It would have to be built from scratch. Since you indicated you are not capable of doing it yourself it would probably cost over $8-10,000 to build a intercooled KB/blower drive on a dohc 5.4.( I also do not know anybody that would take on a project like that)
It would also require a built engine to take the boost ...Pony up another $7-10,000. The necessary fuel system and assorted minor stuff..(Custom headers, Mass air,Injectors, Pump, regulator and lines..Another $3-4,000. I forgot transmission/clutch...$3,5-4,500
Regards....
Maybe i should have said....AWESOME!! It can be done for $3,000 ?
So...How's the project?
