Well big thanks to paul for all the expertise along the way. here's the skinny on what we did this weekend

Ported intake manifold from 2006 F150
Swapped my stock IMRC plenum back onto the new one
New motorcraft spark plugs gapped to .050"
New valve cover gaskets (they used to seep a little)
Cleaned valve covers
Cleaned the stock COPs and filled with dielectric grease
Cleaned intake ports on the heads
Cleaned MAF sensor
Cleaned Throttle body and Plenum
"Sniper" tuned for 93 octane
Replaced my coolant bypass line from old TB heater
Replaced charcoal purge valve vacuum line

Now onto the pics. I dont have pics of everything it would take forever to post all that. here is the important stuff.

Started the tear down




Intake manifold comparisons

 

The heads were very clean for almost 70,000 miles




Paul cleaning up intake ports on the heads, and the valley area


Going back together



Top of manifold

 

Belly up


Side of plenum and TB


Ported plenum


Ported TB



Ill have a few vids up after they UL on youtube, so stay tuned

Thanks,
-Patrick

 

Looking good Pat. Any plans on dyno-ing the truck with the 93 tune?

 

Not yet, still got a couple things left to do before it hits the dyno

Here's the three videos:

after swap, still on 87 getting some base runs in to monitor A/F and timing (2 passengers)
http://www.youtube.com/watch?v=p7ol8eEr8FU

Base 93 tune, 2 passengers uphill run
http://www.youtube.com/watch?v=8W6IidF-zTU

Final 93 tune for now, might bump timing more for a track run. (1 passenger)
http://www.youtube.com/watch?v=EksGvMjGtjY

 

Nice vids, sounds great too.

 

Nice work Patrick. So the porting has been the big secret project!

 

just one of many projects but not the one i was talking about the other night

 

Nice job Pat and great pics. Find any problems?

 

did you actually get those crappy gaskets to seal in the back? I had to do mine 4 times because antifreeze kept leaking out the back port on the passenger side, it was leaking down the around the bell housing. I ended up using the stock original gaskets that had 60,000 miles on them because it was a Sunday afternoon and i couldn't find any in the city. I can now replace the gaskets in less in an hour start to finish.

 

Did you match the head ports to the gasket? If not where the intake is ported it is wider than the port wall on the head.

 

Good work. That's the first PI 4.6 mani I've seen up close.
What is the little tube coming up from the crossover, and where does it go?

 

HI!... Yay, if you don't port match the intake to the heads, you really didn't accomplish anything. You most likely lost flow due to the incoming air into the heads from the intake manifold is now hitting a huge lip, and causing turbulence. You don't have to port the heads intake ports much. Just enough to smooth out the transition from the intake manifold to the heads.

Like this :

 

I didnt see huge gains, but i saw most gain from 70-90

crossover? That little 1/4" port in center of intake up front, goes up to original TB warmer, and then back to a coolant T pipe just behind the intake.

we didnt touch the heads other then clean what we could really well.

so far no leaking gaskets, with almost 100 miles of very hard driving

 

not too bad! looks good