5.4l 2v intake build

[96blak54]

Since I sold my HPS 5.4l 2v intake back last summer due to hard times, I have decided to build my own from a few stock truck intakes. My original plan was to move on from 2v to 4v and build an intake to use, but im struck with trying to extract what I can from a 2v.....npi heads at that. I am also one of these rare breed individuals that continually challenge myself with projects. I figured the masses at sn95forums would appreciate the build along with me, so ill keep this updated with pics. And please ask questions and post your ideas!

The first 4 runner of 2 intakes will but whats used for a complete intake. This will keep the runners close to the same length and it will have a coolant crossover for the rear of the engine as well. So, yes ill use one front like normal and the second front spun around 180° butted up to the other with the crossover on the rear.

 

[96blak54]

Next step is to cut the second intake and clear off all the un-used bosses, flashing, and unnecessary aluminum. Ill be using stock mustang fuel rails so im gonna have to weld in some mounts for that.

 

[330CubeGt]

I've done this before, after I cut mine up the next step was the scrap pile lol ao I'm curipus to see what you come up with.

 

[96blak54]

Your curiosity inspires my drive to produce a finished product....lol. I remember after doing my 5.4l swap, I watched you do yours with great success.

Its to bad more dont swap because the fun factor sky rockets at a very reasonable cost. Its just to complicated to intake one under a hood with reasonable power production.

So...I have to ask....why did you scrap the intake project? You succeeded well with all the projects you have done....

 

[330CubeGt]

Good luck man, i hope it comes out sick!
I passed on my knowlege to a buddy last year. This was the last 5.4 swap I did.

Not as popular as it was, but the new 5.0 has a lot of peoples attention some have already started replacing there snives.

 

[96blak54]

The 5.0l is a powerplant! But a costly one at that.....well technically equal to most boosted applications. Still though...lol....some of us folks have wifes, kids, bills and not enough fund for bigger dreams. Besides im humble with rumble on the cheap. I know their are others out there too.
My expectations are at least 310rwhp n/a on pump gas with a but load of torque. I feel this is a good achievable goal to set with factory heads and then move on to trickflows. My last npi 5.4l ,very mild build ,netted 281rwhp and thats been 7yrs ago, but ive learned alot since then.

So...in the next few days ill scavenge another intake, will continue to port on another exhaust port in the heads, and 30° back cut all the valves. I would like to use aftermarket valves or at least modified pi valves ....who knows.

 

[96blak54]

A little update on a project I started a while back. I got the intakes hacked and tacked together. I took it to work and sandblasted it pretty. Plopped it up on the mill and squared the ports up even and equal length. Now on to cutting the aluminum plate and tacking up a finished product.

The pic is pre- milled.

 

[D3VST8R96GT]

I want to do a na 5.4 build..... honestly you're the only person who ever talked about it..... imagine some flat top pistons and some custom billet rods to (some call for taller pistons)....

 

[96blak54]

Oh yes...CH1.320" pistons are needed to get the "squish" or .110" longer rod. Hopefully by summer ill have her rolling again. This foundation will be set for future plans. The intake and 2v will serve as temporary for the finished build. Plans are to extract what I can with npi heads ( LOL ) Which reminds me, I need to post up my findings about the early made '95npi heads. Very interesting!

 

[96blak54]

A tad bit more progress. I took some .250" thick aluminum laying around, cut into equal lengths and welded (literally went crazy) to the prts entrance. The idea with the overly excessive weld...lol....so I can bell mouth the port entrances. Intricately welding aluminum at impossible angles with a spoolgun aint pretty,....if you havent noticed...lol. Tig welding is the pretty preferred method. The weld quality from the pic looks horrible, but better in person. It penetrated/ solidified well and their is plenty there if I decide clean up the looks.

 

[96blak54]

Delete

 

[96blak54]

Delete

 

[96blak54]

A little more build time! I suck at welding! But it will hold! Aluminum is tough to weld with anyhow unless a tig is used. All I have is spool gun. It'll work!

Still undecided if Im going to make a removable lid. I am going to use a cobra throttle body to help keep it low enough to fit under the hood, although I believe im past that point. Probably have to cut a hole in the hood to shut it. Ill move towards a cowl then.

 

[D3VST8R96GT]

What about a front inlet?

 

[03DSGGT]

Very cool project, can't wait to see the results!

 

[96blak54]

Thanks guys. More than likely, a cowl hood will be needed, a front inlet is a genius idea!

 

[D3VST8R96GT]

3v cai flipped over to use stock maf wires

 

[D3VST8R96GT]

Only issues I can think of .... Alt height and coolant hose height

 

[96blak54]

Yes, its all taller cause of the 5.4l, but you already know that. Since the intake is 2 front intakes hacked together, it basically has the coolant mod. I got to figure out how im going to tie the rear to the front.

 

[96blak54]

A little bit mo progress! The intake needs a lid. Just so happen to have 3 pieces of this half inch thick aluminum plate laying around the shop. Together they made a perfect fit.

I gotta say, when the material thickness is right for the welder size, it welds out beautiful. Not that this is really good. I just turd'd it on there, but dang did it weld out nice. Alot better than the intake itself.