4bbl/Dual Exhaust install on my Ford Inline

[newrider3]

Finally started the swap on my 300ci Ford 6cyl. I'll let the pics do the talking.

Bought a used Clifford intake, and the carb flange was pretty afro engineered. Was also on there the wrong way for the carb to be centered properly.

So I took this:

And added some of this to get it to fit.
I <3 the mill.

Before shot, what a mess. When I went to pull the stock carb it was loose as hell, I'm sure that really helped it run better.

MIGHTY 1BBL!

Old stuff, including cat (wut?) EGR valve (???) and log manifolds (also known as boat anchors).

Stripped:

Mufflers hung in place of cat, using original hanger:

Alt mount with smog pump mount chopped off, to make room for the split manifolds:

Mockup of exh manifolds, getting ready to make custom downpipes to the mufflers using mandrel u-bends:

 

[freakboy]

Swweeet stuff here dude... i cant wait till i get the parts for my 300.. basicaly same thing as yours except theres gona be a mild cam and a turbo

 

[Rustydog2010]

Wheres the twin turbos? ;-)

 

[newrider3]

PITA to do on one of these without getting into the internals, and custom building an EFI computer...no thanks.

Pretty much spent all evening yesterday yelling at the exhaust; got the head pipes and some straights from the mufflers in, just trying to connect them now.

 

[newrider3]

pipes made.

 

[newrider3]

Terrible port match from the factory, one of the biggest bottlenecks in these motors.

After some dremel action (a rag and wd40 down the ports keeps out the shavings):

Fitting the exhaust manifolds:

3/4" pipe plug for the EGR port

Forgot to get a pic of the intake mounted, but here it is with everything pretty much bolted on:

Custom carb studs:

Some jackass put a heater box in the space my aircleaner was supposed to occupy so some grinding was in order.

Sooo much cleaner than before, from a bunch of spaghetti, to only 2 vacuum lines and no wires.

 

[timmytim]

pipes made.

What technique did you use to butt pipes together?

 

[newrider3]

As in to hold them for tacking? Masking tape is good enough for four tacks or so to get it ready for full welding. All the cuts in the bends and straight lengths were done by eyeball and tape measure while working underneath the truck, not sure if I would ever do it that way again. I had to get two cats installed in this system at the end of the summer and I ended up subbing it out to a shop rather than screw with it myself again...

Since this is a pretty old thread, here's my FTE build thread from this point on, much more progress has happened since the last post here...
http://www.ford-trucks.com/forums/874651-newrider3s-f-100-a-5.html

 

[timmytim]

As in to hold them for tacking? Masking tape is good enough for four tacks or so to get it ready for full welding. All the cuts in the bends and straight lengths were done by eyeball and tape measure while working underneath the truck, not sure if I would ever do it that way again. I had to get two cats installed in this system at the end of the summer and I ended up subbing it out to a shop rather than screw with it myself again...

It looks like you got one pipe to fit into the other pipe before you tac them?

 

[newrider3]

Nope, straight butt welds.

 

[timmytim]

Nope, straight butt welds.

I have a similar job to do on my ford 240 6... I have the eft manifolds. Can you tell me how many elbows you needed for job and how many 90,45 or 15 you needed thanks..

 

[OzFab]

WOW, nice work, I bet it made a difference.

One thing though: You mention a cat (catalytic converter) & the old carb has electrics so, I'm guessing, this engine is rather modern (1980s?)

The reason I ask, we haven't seen a Ford engine like that over here for over 40 years. In the early 70's, Ford Australia (I think) developed the "crossflow" engine with the intake one one side of the head & exhaust on the other. It turned out to be a very useful & productive design which is still used to this day

 

[newrider3]

I have a similar job to do on my ford 240 6... I have the eft manifolds. Can you tell me how many elbows you needed for job and how many 90,45 or 15 you needed thanks..

I don't remember, and honestly it wouldn't help you anyway because I can guarantee your exhaust will be different... I only used 180 degree u bends and cut out what I needed.

WOW, nice work, I bet it made a difference.

One thing though: You mention a cat (catalytic converter) & the old carb has electrics so, I'm guessing, this engine is rather modern (1980s?)

The reason I ask, we haven't seen a Ford engine like that over here for over 40 years. In the early 70's, Ford Australia (I think) developed the "crossflow" engine with the intake one one side of the head & exhaust on the other. It turned out to be a very useful & productive design which is still used to this day

Yep, you guys got the crossflow head, many of us are pretty jealous of this fact... Ford was working on a bunch of stuff for the 4.9/300 six here like a crossflow head, and even cylinder deactivation... The whole program was scrapped when they decided to scrap one of their best engine designs because they didn't want to update the emissions and fuel mileage.
The stock heads we have require a ton of work to even support a new cam and carb, I ported and polished mine while I had the truck apart two summers ago and it made a big difference in addition to all the other mods (see the FTE thread for the most recent engine work).

 

[jamyers]

If you haven't already, you need to check out www.fordsix.com. TONS of great info there!

And as an aside, I find it interesting that there are a bunch of Aussies on both boards...

 

[machinist@large]

If you haven't already, you need to check out www.fordsix.com. TONS of great info there!

And as an aside, I find it interesting that there are a bunch of Aussies on both boards...

Personally, I say the more the merrier; it's one of the things that helps to keep this site fresh and interesting.

 

[jamyers]

Any updates on this project?

 

[newrider3]

Since this is a pretty old thread, here's my FTE build thread from this point on, much more progress has happened since the last post here...
http://www.ford-trucks.com/forums/874651-newrider3s-f-100-a-5.html

.....

 

[timmytim]

180 degree u bends cut to fit, thanks...Im new at welding and have a glassless 100amp stick welder. Could you tell me what settings on ure welder you used and the type of stick i could use to weld the pipes?

 

[devino246]

180 degree u bends cut to fit, thanks...Im new at welding and have a glassless 100amp stick welder. Could you tell me what settings on ure welder you used and the type of stick i could use to weld the pipes?

99% chance he used a FCAW or GMAW welder, not a SMAW (stick) welder. Stick welders don't weld thin metal very well...especially if you're new to welding.

 

[newrider3]

Yep, stick welding will turn exhaust tubing into a big puddle of slag before you know it, flux core welding it isn't much easier. At the time I had a 100amp flux core welder I used to carefully tack the pipes together, and I finished them on the nice Millermatic MIG machine at school, using a pretty low heat setting and a stitch welding method to avoid burning through.