Amazing that your truck is 10 years old. Well done!
10 is a big year, your throwing a party
My Brother-inlaw has a 99 Dodge 1500. I was over there today and had to drop in a new radiator for him. What a pain in the butt that was. He keeps up on it like we do and his looks and runs great. Er, I should say, it runs great because he calls me and has me do the work.
Alot people can't believe my truck is 11 years old. I will drive my truck until it can't go anymore. I used to think the body would eventually do it in but I had that all done. Now I have to make sure I keep the powertrain in top shape. This Spring I am doing the throttle body for sure but maybe I will play and do the whole intake. I would really like to put some headers on it and new Cats. I have a good friend who Manages the local Cole Muffler, so I know I will get a great price. My biggest worry is someone hitting me and totaling the truck out. NYS only allows book price no matter the investment unless the vehicle is 20 years old which falls into the "classic" catergory.
Anyway, nice pic's !!!

 

By the way, how many hours do you have on the intake refurbishing. It looks like you did the entire intake, inside and out.

 

It's full of bondo/ - the rocker panels were fabbed from an old Kenmore dryer -

I'm over a 1/4 million Michigan miles on her now - I hide the rust well. You can't see it on the outside unless you look real close, but I've done bodywork the last three winters - freaking HATE body work! I'll play in the snow with it, but try to avoid the salt - It eats thru quick.

 

Not sure, - worked on it here and there. Not that many, couple hours.. I had to port the plastic lower intake as well, - many factor/casting defects. I had to port match the upper and lower once together. The two didn't match up. That didn't take long. Also, the gasket dowel for the was 1/4", the manifold dowel hole is 3/16 ? That didn't fit. I was curious and looked at a real old set of gaskets Ford used when they replaced my motor in 2000. They cut the dowel off the gasket, figures... - I drill the manifold out to receive the 1/4" dowel.




Here , I made you a video since you asked, it's not much . Setting up to port -

http://picasaweb.google.com/jbrew393...23118432254354

 

Anyway , that funs over -




New radiator shroud should be here tomorrow, - if it doesn't fit, I'll have to run over to JMC's and grab his old one.

tjk, - what did your new coils say on them / you remember ?

 

A pic or the water jacket damage that was repaired. All jackets (8) @ the heads and the manifold were corroded and deep. I had to grind these out with dental bits in order to fix and clean with paint prep. Then filled with permatex metal filler/ plane down/resurface. -



BTW - There were know signs of leakage when I first disassembled. You can usually tell if a gasket was leaking - I don't think they were. They most likley would have in the near future if I didn't repair. I'll replace the heads and manifold in another 50,000. - If it runs that long

 

WOW, look's awesome.
I just checked the COP that Global sent me recently. The only numbers on it are "T 08.06", which I think is a manufacturing date. On the top of the plastic where the harness connector plugs in there is a "B+" which is part of
the plastic injection mold process.
I don't think there was any info on the previous 8.
When I get around to putting that COP on my # 3 cylinder, I will look at the rest.
After about 15-20 emails (some were almost to the point of harrassing),
4 weeks of waiting, they caved in and sent me a COP.
They had me send different info a few times including paypal reciept twice, shipment confirmation twice etc etc. I will never go back to Global.
Last week, the guy from Uneeksupply emailed me through Ebay to thank me for his recent orders and that people were mentioning my name and the F150online.com forum. He saved my email address from when I inquired about his COP's and stated that there were problems with Global and to probably expect some orders. Anyways, he said when I place an order that he will give me a "great" discount for the extra orders he has filled. Pretty nice of him.
He also stated that he checkerd out the forum and was pretty impressed with how it is set up and the help everyone recieves for free by just asking.
I am thinking about taking him up on his offer and putting his COP's in my truck. I will probably sell my Global's to someone on here if they want them.
They may have only 1000 miles on them so I will try to get $40 - $50.00 for them. $50.00 if I pay for the shipping.

Anyways, nice job on the intake. I don't think you will have a problem getting another 50k out of that motor unless something catastrophic happens.

 

I was wondering if you got an off set or something. They don't say "GAMMA" in white letters. My old global set does as well - just smaller white lettering.

Nah , I don't want them if they don't have that on there somewhere.


Did you see the vid?

 

Good lookin truck Jbrew!!!

 

Oh yeah, looking good for sure!

 

lol haha nice mod with the vacuum cleaner. makes for less mess but a lot of noise

 

Seen the video.

Was that your lower intake?
I am waiting for the video of the entire job when it's completed. I want to hear the engine running after all the mods are done. Looking forward to a report on the Denso's you put in as well. Interested to see if you got any gains out of them after you put a few miles on the truck. Will be tough to really notice anything until the nice weather comes back.
I am really considering doing the same work you are doing now except my horn works and I havn't broke the starter yet.
It's either that or picking up a new project car. I sold my last project in 2007.
Loved that little Mazda when I got it done. Made good money on it too.
If I put any more time and money in my truck, I will probably catch some grief from the Mrs. I would really like to do a muscle car but everything around here is NY winter crap. I will have to start searching AZ. The prices are a better there than GA or FL and if I am going to take a trip I would much rather go to the Tempe area. I will be going down to NC/SC for my Nieces wedding in October and would like to look around that area as well.

Your project is looking good for sure !

 

Thanx fella's - Yea , that's my intake lol.


Not sure what it's going to sound like, has a new Magnaflow muffler on it now. - Should be quieter with like a low rumble I imagine, but I don't know. It won't be right until it's tuned.

I'm finding out the more I increase flow - the worse it runs under normal conditions. It won't tow an empty trailer down the e-way without downshifting on the hills. It never use to do that.

It will go like hell wide open, but 90% of the time I don't drive WFO. That's what I need to fix after I get her fired up. It's getting tuned this time. That's what this is all about.

I wouldn't be taking sh^t apart and breaking things for know reason - Well okay, not this time anyway. Trying to get its strength back up/prepping to tune. With high miles, I'm not sure it will happen. I might need a new one.

What bothers me is that it's running so lean - Plugs had about 20,000 on them and they were toast. Electrode wore and they were all white. To hot /wrong heat range ? That's what it looks like - Not so, it has to be lean, really lean. I'm hoping it's because of the tune.

I was hoping to find something wrong with it by going thru it. All I found was a marginally bad tensioner , tensioner pulley and idler. My monitors all run and test quick (even the EVAP). Just because I'm within parameters doesn't mean everything's cool I take it.

SOOO - After I get her back together I'm going over to chips and programming forum for awhile for a higher learning. Not sure who or what yet - VMP, Troyer or PCP (PHP?) - I'll go with one of those guys.

The good thing - If this doesn't work, I can swap what I've invested over on a new motor.

 

That's strange - Just went thru my new coils to make sure they were 508's - I only have 2 508's out of the 10. The rest tested out @ 538-540 thru secondary resistance.

Tested the set I was running and those are all 491's

Tested a previous set of Globals = 491's

Set from a Mustang = 508's

Well, I installed the new Globals, but kept the two 508's separate for ignition integrity.. I'm not sure if a higher resistance is good or bad ? I'll find out tho.


Ahhhh, FEDEX is in the driveway now - Must be the radiator shroud - Wonder if it's going to fit..?

 

what u using for a tune? sniper?