98 Expedition Turbo build

[qcksnake]

This is my first post here, I am generally a lightning and mustang guy but i am a ford guy at any rate. Wanting more room when towing and needing the power of a lightning, the only choice was an expedition. I am an Anti-Diesal guy so a diesal wasnt in the question. Sorry but i just prefer a gas burner, I cant stand all that knocking!

At any rate, i built a 97 last year and it succombed to the ford cruise control deal and burnt to the ground, and of course i had only liability on it. So i salvaged what i could from that build and I am finally back at it.

Here is a few pics of my progress and i will keep this thread updated through next week when i finish it up. The 98 i bought has rear heat/air so its going to make the downpipe awful fun!
I managed to salvage the built trans i did for the 97 and the bottom end and most of the pipes on the hot side.

Any questions please feel free to ask.

I started by moving the ABS( i just delete it on lighnings but the 4wd needs it for the GEM module) and doing the electric fans, mounting the intercooler(I am doing Air-Water).








In the pics you can see i also trimed the tops of the control arm mounts. A neccesity with the 4WD, Not neccesary with a 2wd.

 

[qcksnake]

Circuit breakers for fan.


Added 2 walbro 255 in tank pumps...............

 

[qcksnake]

Driver side hotside pipe with flexjoint

Pass side hotside with wastegate flange and turbo flange

The manifolds are a stock 4.6 truck manifold flipped on the pass side, the driver side is a factory mustang 4.6 2v driver side manifold. I cut the egr tube and welded it shut.

Here i am getting ready to raise the engine

 

[toms89]

Very cool! It will be awesome to have a turbo Expy here!!!

Subscribed...

 

[timberwoof]

Sweet build. Gotta subscribe to this one.

 

[sgtowing]

Welcome. How much hp do you think you'll make?

Sent from my DROID BIONIC using Tapatalk 2

 

[qcksnake]

Thanks for the comments!

I think it will be around 500RWHP on a mustang dyno give or take, Say maybe 600 Rear wheel on a dynojet or so. Depending mostly on the tuneup that I run, I might make a lower boost 87 octane tune for daily driving(i would expect around 440 Rwhp on that one or so).

I have good bottom end parts and i worked the heads, If this was a stock motor the 440 would be all i was comfortable with.

Of course on race gas and with more timing it could get wild>At any rate if i decide to have fun with an unsuspecting sports car it probably would suprise them or maybe even outrun em?


The turbo for this build will be a Borg Warner 67mm with a .91 Divided backside.
I will get some engine pics up tomorrow if I have time.

Here are the motor mounts complete, I had to slot the holes for the bolts and slide them up too, Just raising them makes the holes go inboard as well, so you have to slide em out, It makes putting the engine in a real JOY! I just used some bar stock I had laying around. On the last one i didnt figure this out until the motor was in the truck, so i just took some 3/8 plate and used the plasma to cut it out, lifted the engine with a jack and slid em under, Then i welded them to the frame and the mounts without taking anything off! This one looks a little cleaner though!





Put in some air bags as well for towing.

 

[GAINMOB]

nice work...welcome to the site...where in NC are you?

 

[qcksnake]

nice work...welcome to the site...where in NC are you?

Thanks.

I live near a little town called Bennett, I am about 1 hour south of Greensboro, 1hour from Fort Bragg and 30 Min from the NC Zoo.

 

[rburch]

Welcome! Nice build!

Subscribed!

 

[qcksnake]

Welcome! Nice build!

Subscribed!

THANKS!

I got a little done this morning.

Here is the bottom end pics.

Its pretty sturdy,
ARP Main studs, Manley H-beams with ARP2000 bolts, CP -16cc dish pistons, HV oil pump and pickup from 03 cobra. I also put in some total seal stainless rings for extra durability.



Got the heads and manifolds on!


Here i am extending the 02 harness to reach the front.


Couple of pics to show how she sets now with the motor mounts modded and the ABS set back. Kind of shows what i was moving stuff around for. I have to move the Power steering reservoir as well.

 

[toms89]

Your exhaust manifolds are on backwards!!

lol...yes I know turbo!

Looking good!

 

[qcksnake]

Your exhaust manifolds are on backwards!!

lol...yes I know turbo!

Looking good!

Yea, it does look a bit funny!

A few things to note in the pics, I canex the factory PCV system and holesaw the valvecovers for one of these. http://www.jegs.com/i/Moroso/710/25900/10002/-1?parentProductId=751825#moreDetails
You have to run straight thru mufflers, These will not work with a chamber style. The main reason is because with the factory PCV system the boost levels will defeat the pcv valve and counteract the pcv system altogether on one side, on the other the turbo (or blower for you blower guys) will suck so effeciently that it will suck up more oil than you want in the intake tract. You can just vent the crankcase, but that cost power. This system works well and wont oil down the intake tract, or dilute the incoming air/fuel mixture and sacrifice octane. A vacuum pump is the best deal but this is just a tow rig after all!

On the pan i ordered a drain/feed line kit and i went ahead and welded a -10 fitting in the pan below the Harmonic Damper. I also have a brass T to get oil to the turbo that will go in where the oil pressure switch is as well.

You can see the turbo mount(to keep stress of the turbo off pipes)this will prevent the pipes from cracking and sagging as well.

 

[rburch]

Lookin good! Great pics!

 

[TexasAngel34]

Awesome build.... subscribed for sure

 

[qcksnake]

Awesome build.... subscribed for sure

Thanks again!

I got some stuff yesterday, Didnt have time to stop and post pics. SO here is the work from yesterday. I am finishing the exhaust and the intercooler plumbing today if i get that far.

Hotside wrapped and ready for install.


Turbo!!!!!! Just a lil Borg Warner 67mm


As you can see i use a large 60MM wastegate, a 44MM would do fine though.


Here is the dump for the wastegate, I would like to run this back in with downpipe, but with the rear heat/air its impossible. Hard to do on this setup either way. IT will open when at full throttle, and i made a little baffle to go in the end. Wrapped it as it goes near the oil drain, i also wrapped a lot of ac lines that are in contact with downpipe.





Hard to tell in the pics but i used oval tubing, the transistion from the 3.5 inch Borg warner turbo flange was fun!

Here i have the downpipe in and the vbands welded and it tips back under the truck here.

 

[qcksnake]

More downpipe. I have a bung in there for the wideband as well.



In the pic above i added a iat sensor from a lightning in where the EGR previously went. I am going to have my tuner build a file in the truck to take away timing if the IAT temps get out of hand. This will not be an issue, i have tested the Air/Water setup like this and it works very well. The posiblity of the intercooler pump failing is enough to do some damage though!

 

[rburch]

Lookin good!

Chuggin along!

 

[superexpy]

 

[tallsville]

nice build.