R
rocket5979
Guest
Update Days 5-6-7:
Well the Flex-a-lite fans, JLT CAI, and PA Performance 170 amp alternator came in a few days ago. I must admit I have been kind of lazy and dragging my feet on this project. hehe. Yesterday I didn't do much to the truck and finally today I got motivated in the later afternoon and really kicked ass till now. I got quite a bit of custom stuff done in such a short period of time.
The Fans are going in ok. I still want to fab a bracket to firmly mount them onto but they are placed and aren't going anywhere.
The alternator arrived. I was very happy till I seen that it has a totally different plug than our stock Explorer alternator regulator. One more thing to order and wait on.
I did try a few test fit serp belts to give me a better idea of what length I will need. So far it is looking like a 119" belt will do just about fine.
I dove into the electrical the other day. Things went really well, especially considering that I hate electrical work. I had to modify/lengthen the TPS, IAC, ECT and MAFS/IATS harnesses. The TPS & IAC harnesses I had to add about 6" to. I also had to add about 6" to the ECT harness to allow it to crossover to the passenger side. Being that the stock MAS system places the IATS in the MAS itself I had to relocate it after boost in the KB manifold. Simple procedure of cutting the two outside wires doing some fancy connector work along with some very sexxy soldering and it was done pretty quick and looks factory too, well maybe a little shinier.
Now onto the big stuff. I got about 90% done on the instercooler setup today. I am quite surprised I made it this far in such a short amount of time being that I took the front end off the truck to do it. All the IC overflow tank and pump are mounted in a totally different location and with different mounts. The IC radiator itself was a tight but pretty much perfect fit under the bumper. I had to "clearance" a few things, but once done it all fit really well. Part of the bumper mounting bracket had to be cut off to allow IC hose passage through the area. Overall it is getting to be a very very tight fit with everything in the engine bay now. The CAI is squeezed in there just barely. If it were literally 1/4" longer I would not have been able to use it. I thought about relocating the radiator overflow and cruise control module to the rear about 2-3" to give things more room but surprisingly it all fit in there ok. When I swap the built engine & tranny in there I will reconfigure stuff and fab my own heat shield box and pull air from the bumper and fenderwell. It will get some hot air into the intake as is, but it will be just fine for the power level I plan to be at.
Things left to do:
Alternator wiring
Fan wiring
IC pump wiring
KB BAP wiring
Fab fan brackets
Here are a few pictures...
Well the Flex-a-lite fans, JLT CAI, and PA Performance 170 amp alternator came in a few days ago. I must admit I have been kind of lazy and dragging my feet on this project. hehe. Yesterday I didn't do much to the truck and finally today I got motivated in the later afternoon and really kicked ass till now. I got quite a bit of custom stuff done in such a short period of time.
The Fans are going in ok. I still want to fab a bracket to firmly mount them onto but they are placed and aren't going anywhere.
The alternator arrived. I was very happy till I seen that it has a totally different plug than our stock Explorer alternator regulator. One more thing to order and wait on.
I did try a few test fit serp belts to give me a better idea of what length I will need. So far it is looking like a 119" belt will do just about fine.
I dove into the electrical the other day. Things went really well, especially considering that I hate electrical work. I had to modify/lengthen the TPS, IAC, ECT and MAFS/IATS harnesses. The TPS & IAC harnesses I had to add about 6" to. I also had to add about 6" to the ECT harness to allow it to crossover to the passenger side. Being that the stock MAS system places the IATS in the MAS itself I had to relocate it after boost in the KB manifold. Simple procedure of cutting the two outside wires doing some fancy connector work along with some very sexxy soldering and it was done pretty quick and looks factory too, well maybe a little shinier.
Now onto the big stuff. I got about 90% done on the instercooler setup today. I am quite surprised I made it this far in such a short amount of time being that I took the front end off the truck to do it. All the IC overflow tank and pump are mounted in a totally different location and with different mounts. The IC radiator itself was a tight but pretty much perfect fit under the bumper. I had to "clearance" a few things, but once done it all fit really well. Part of the bumper mounting bracket had to be cut off to allow IC hose passage through the area. Overall it is getting to be a very very tight fit with everything in the engine bay now. The CAI is squeezed in there just barely. If it were literally 1/4" longer I would not have been able to use it. I thought about relocating the radiator overflow and cruise control module to the rear about 2-3" to give things more room but surprisingly it all fit in there ok. When I swap the built engine & tranny in there I will reconfigure stuff and fab my own heat shield box and pull air from the bumper and fenderwell. It will get some hot air into the intake as is, but it will be just fine for the power level I plan to be at.
Things left to do:
Alternator wiring
Fan wiring
IC pump wiring
KB BAP wiring
Fab fan brackets
Here are a few pictures...