“Thunder” 1998 Expedition Build Thread

MISTERgadget · Aug 9, 2016

My understanding is that the headers will work but the midpipes won't, the transfer case is in the way. It should be easily adaptable with a couple of bends though, it's not much different. IIRC, Pacesetter sells headers and midpipes that work with the 4x4, although they are not stainless like ARH and the midpipe has a Y pipe into a single exhaust.

reece146 · Aug 9, 2016

I'll have to crawl under and have a look when I get a chance. The truck is still on the jack stands from the radiator support replacement I'm doing so it's just a matter of going out and looking.

I could live with a single out but would rather fab my own in stainless. Stainless is so nice to weld it makes it a fun project. Maybe this winter... I pulled the fenders off my truck for the work I'm currently doing and the exhaust manifolds are all exposed asking to be replaced... must resist - no time currently and I miss driving my truck.

I was researching headers for these trucks a number of months ago but didn't see anything in the way of a long tube header. I didn't think to look at Lightning parts - only plain F150. This thread has kind of made my day.

Btw, you went 1-3/4 instead of 1-7/8 primaries? Was there a specific reason for that? NA vs SC plans or something else? I haven't done any math on this re: flow vs displ vs rpm yet so don't know what is appropriate. My truck is just going to be "simple" bolt-ons so not looking for crazy power. Just looking to tow the trailers a little more effortlessly and have fun with the truck.

Are the O2 sensors for the emissions equipment further downstream than stock? Expecting any issues? I've heard some vehicles are really sensitive to heat loss on the O2s but I have no data on these engines.

Thanks!

MISTERgadget · Aug 10, 2016

reece146 said:
I'll have to crawl under and have a look when I get a chance. The truck is still on the jack stands from the radiator support replacement I'm doing so it's just a matter of going out and looking.

I could live with a single out but would rather fab my own in stainless. Stainless is so nice to weld it makes it a fun project. Maybe this winter... I pulled the fenders off my truck for the work I'm currently doing and the exhaust manifolds are all exposed asking to be replaced... must resist - no time currently and I miss driving my truck.

I was researching headers for these trucks a number of months ago but didn't see anything in the way of a long tube header. I didn't think to look at Lightning parts - only plain F150. This thread has kind of made my day.

Btw, you went 1-3/4 instead of 1-7/8 primaries? Was there a specific reason for that? NA vs SC plans or something else? I haven't done any math on this re: flow vs displ vs rpm yet so don't know what is appropriate. My truck is just going to be "simple" bolt-ons so not looking for crazy power. Just looking to tow the trailers a little more effortlessly and have fun with the truck.

Are the O2 sensors for the emissions equipment further downstream than stock? Expecting any issues? I've heard some vehicles are really sensitive to heat loss on the O2s but I have no data on these engines.

Thanks!

The 1-3/4" headers are fine for 700+ rwhp so I didn't see myself needing a larger primary. In fact, most of the Lightning headers out there are 1-5/8" primaries, so the 1-3/4" is plenty really. I have a Lightning as well, that truck made 470 rwhp on 1-5/8" primaries and dual 2.5" exhaust, and now with my turbo setup on the Lightning it makes 1040rwhp with 1.75" primaries, so it's not really a bottleneck, and gives you a little more space during the install and around the ABS and wiring. My goal for this truck is 500rwhp, so these should be plenty.

I haven't run into any issues with the o2s, although there's not too many miles on it just yet, never had an issue with my Lightning or mustangs running longtubes and the rear o2's either, I think these ecu's just aren't that sensitive to it.

Most tuners will adjust slightly for the primary o2s being further from the cylinder heads, but the rear o2s aren't picky at all.

MISTERgadget · Aug 15, 2016

Status update on where things stand today

Heads are at performance CNC for porting, oversize valves, and assembly with upgraded springs and retainers

Engine block is at the machine shop for line honing and boring with a deck plate

Pistons, rods, crank, oil pump w/billet gears, ARP hardware and a few other parts are all with the engine builder, waiting on the heads and block to return

In the meantime, I cleaned up the supercharger, intercooler, intake manifold, and midplate, and got them assembled into a little shrine in the corner while they wait for the engine.

The polished blower isn't quite what I had in mind since it doesn't fit the "could have been stock" theme, but I just couldn't walk away from the deal I was able to get on it. Might still try and trade it for one of the black powdercoated superchargers or do a silver vein or similar powdercoated finish on this one.

hartsemperfi · Aug 31, 2016

This vehicle is gorgeous and yes very inspiring. You have given us all something to think about well done.

Texpedition · Aug 31, 2016

Just got new leather for the front seats and arm rests. Last week it was a replacement for the tensioner and before that an overhaul of the intake manifold and replacement of related parts. Next up is a new '99 bumper. Then a new '99 grille and then on to the Lightning bumper cover.

Tjhoward84 · Sep 7, 2016

Just found this forum. What you are doing to your truck is what I did to my '99 back in 2013 except I had someone do it as I don't possess the mad skills you have in order to pull this off myself. I love everything you're doing. The only difference is my is a 4x4 and I found a zero mile (brand new) Lightning crate engine in someones wearhouse - never been installed.

Here are some pictures.

I have a ton more pictures but these were on my work computer.

The highlights are:
2001 Ford Lightning Crate engine - zero miles
Long Tube SS heads w/high flow CATS and 3" SS all the way out the back
Stock Eaton blower that's polished and the Intercooler ported by Stiegemeyer
Completely built trans and transfer case
Lowered with Ground Force Lower Kit
Hotchkis Front and Rear Stabilizer Bars
Updated brake rotors and pads
OEM Lightning Headlights and Corner
Stillen Gen 2 Lower Lightning valance

hartsemperfi · Sep 7, 2016

Oh my

Tjhoward84 · Sep 8, 2016

MISTERgadget said:
Hi Alex - as a base for the headlights I used generic Lightning replica headlights from ebay, along with this kit from TRS:

https://www.theretrofitsource.com/c...orimoto-mini-stage-3-kit-h1.html#.V6d8m2grLIU

I added Apollo 2.0 flat shrouds, etched lenses, and 100mm switchback halos.

Found them on ebay while browsing. Every once in a while they pop up.

South America, Europe, Middle East, Asia? I'm sure they went all over.

Can you elaborate on how you fit the mini H1s into the Lightning headlight shell? Also, what size (mm) of XBS 2.0 Switchback Halos did you use?

Thanks and great thread.

eluther3 · Sep 12, 2016

Love this thread

“Thunder” 1998 Expedition Build Thread

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