Problems with HCI swap

topless95 · Dec 31, 2008

Everything has gone great until I went to bolt the upper intake on(Edelbrock performer), it sat too low and hit the valve covers(tall ford racing, due to roller rocker clearance) so I ordered a 1/2" spacer and now the upper is on. Now I go to bolt the elbow(professional products) on to the upper and the bottom ear for the egr hits the valve cover, so I cut the ear off and I made a egr block off plate. So finally I go to bolt up my throttle body and it hits the valve cover, so I have grinded and filed it down to try and make it fit. I ended up having to grind down so much where the IAC mounts that I had to grind off the bottom bolt hole. I then drilled and tapped a new hole and then had to use some jb weld to fill in a small portion where the extensive grinding had opened a small cavity of the IAC chamber. Now the throttle body fits and while waiting for the jb weld to cure I am taking the night off. Tomorrow I am hoping to finish this project, and get my baby back on the road.

Is this the usual for this job???

In hind sight I should have bought some chrome valve covers instead of aluminum, that way I could have persuaded them with a hammer where I needed a little clearance.

topless95 · Dec 31, 2008

Oh btw up until mounting the upper the job went so smooth, not one problem.

BlkoutGT · Dec 31, 2008

That sucks to hear, but little gremlins like that always rear there heads, there was a crapload when I did mine, so your not alone..
lol

ryclef331 · Jan 1, 2009

I don't know how tall ford racing covers are but I was able to clear my jegs valve covers when I ran a performer intake but I ran a 1 " spacer and cut the EGR ear off the elbow...but it would not clear a stock hood. As long as that jb weld cures properly and it was clean when you applied it, you'll be good. I've epoxied a couple of egr ports while smoothing adapter elbows and throttle bodys. If you need more clearance...throw a nitrous plate on there! Thats what I run now...clearance AND hp...its win win.

topless95 · Jan 1, 2009

I would have just added a taller spacer, but I just had my car painted and it looks sooo good. Also I am unsure if the guy who painted my car can still do side jobs(he went to a different shop).

I checked the repair and it feels very solid. I think that when I go to a 70mm throttle body I will get a 1' tb spacer so I dont have to go through this again.

302N20 · Jan 1, 2009

I ran into most of the same problems you did with clearances (bec the guy b4 me put on cheap summit valve covers) and did all the things to fix it that u did.
Then I went to put my hood on and it would not close! So I would check your hood clearance. I ended up round off the corner of the rocker arm that was hitting my stock valve covers so i could use them and make everything lower accordingly. the biggest space i was able to run was about 3/8 inch.