Rembrant's new non-Bullnose project

[Rembrant]

I read where you said you re-used the old gears, so you are fine there!

Yeah, that diff was buried in a mud hole (either in the truck, or in the junkyard)

I was just pointing out to anyone that might be regearing (or like me, blew up their carrier, requiring new gears and a full setup that they ought to give them a chance to "court & marry" before....

Oh yes, 100% on the break in, I agree. Maybe I'll do a new gear set someday, but as it was this job was pretty easy the way I did it.

By the way, I did do this one on the bench...the whole axle is up there now. Problem is, since I brought each part to the bench individually, the whole thing is now too heavy for me to lift off by myself haha. This is how I roll.

I haven't updated the old project thread in a while so I thought I'd post up the current status.

I have finally gotten to where all of the big stuff is done, and I now have a whole bunch of little things to do.

The newer engine, transmission, and rearend are all solidly installed, along with a new custom driveshaft.

I left the old dual exhaust in the truck...well, most of it at least, so I needed new down pipes to connect the new engine to the old pipes. I couldn't get any local shops to make the pipes for me, so I grabbed a bunch of loose fittings and made them myself. Got them all together, and then welded every joint.

I have been playing around with the carburetor this week. I had to make some custom covers and gaskets for my new carb to work properly on the old Foxbody intake. It has an elongated hole in it for exhaust, which I assume was to heat the factory carb?

I got that all sorted out (I think?). I'm running a 1" spacer under the carb, but it just barely covered that hole so I made a plate out of 16ga aluminum, along with another wider gasket to place under the 1" spacer. I don't have pics, but the elongated hole is now well covered. I hope it works.

Next issue, was the TPS. Because I'm running an electronically controlled 4R70W (or AODE-W) from a 1996 F150, there's no kickdown rod or cable, so I need to install a TPS on the carb. This isn't really a big deal. It should look like the below pic:

Problem is, my new 500CFM Summit carb came with a rigid dual inlet fuel line that's in the way.

Anyway, not the end of the world, but I'm going to swap out the rigid line for barbs and rubber hoses so I can lower the line enough to give the TPS the room it needs to move.

Other than that, I'm waiting for FedEx to bring me a RockAuto order. Next up is new kingpins and front brakes.I've never done kingpins before, so we'll see how this goes. I ordered an adjustable reamer on Amazon for $24 bucks, so hopefully that does the trick to get them fitted.

Starting this morning (after my coffee is done) to pull the front hubs and see if I can knock the kingpins out. Fingers crossed.

 

[BigBrother-84]

I couldn't get any local shops to make the pipes for me, so I grabbed a bunch of loose fittings and made them myself. Got them all together, and then welded every joint.

https://forum.garysgaragemahal.com/file/n124589/Exhaust.jpg

Nice and clean job!

 

[Rembrant]

Nice and clean job!

It's not "fancy", but nobody can see them anyway, and they'll do the job just fine until I can get the truck running and drive it to a muffler shop to have some new work done later.

[ArdWrknTrk]

I haven't updated the old project thread in a while so I thought I'd post up the current status.

I have finally gotten to where all of the big stuff is done, and I now have a whole bunch of little things to do.

The newer engine, transmission, and rearend are all solidly installed, along with a new custom driveshaft.

I left the old dual exhaust in the truck...well, most of it at least, so I needed new down pipes to connect the new engine to the old pipes. I couldn't get any local shops to make the pipes for me, so I grabbed a bunch of loose fittings and made them myself. Got them all together, and then welded every joint.

I have been playing around with the carburetor this week. I had to make some custom covers and gaskets for my new carb to work properly on the old Foxbody intake. It has an elongated hole in it for exhaust, which I assume was to heat the factory carb?

I got that all sorted out (I think?). I'm running a 1" spacer under the carb, but it just barely covered that hole so I made a plate out of 16ga aluminum, along with another wider gasket to place under the 1" spacer. I don't have pics, but the elongated hole is now well covered. I hope it works.

Next issue, was the TPS. Because I'm running an electronically controlled 4R70W (or AODE-W) from a 1996 F150, there's no kickdown rod or cable, so I need to install a TPS on the carb. This isn't really a big deal. It should look like the below pic:

Problem is, my new 500CFM Summit carb came with a rigid dual inlet fuel line that's in the way.

Anyway, not the end of the world, but I'm going to swap out the rigid line for barbs and rubber hoses so I can lower the line enough to give the TPS the room it needs to move.

Other than that, I'm waiting for FedEx to bring me a RockAuto order. Next up is new kingpins and front brakes.I've never done kingpins before, so we'll see how this goes. I ordered an adjustable reamer on Amazon for $24 bucks, so hopefully that does the trick to get them fitted.

Starting this morning (after my coffee is done) to pull the front hubs and see if I can knock the kingpins out. Fingers crossed.

Cory, that's looking good!

The exhaust in your intake is the EGR port.

[Rembrant]

Cory, that's looking good!

The exhaust in your intake is the EGR port.

Ahh OK, that's what I had thought originally, but my brother inlaw said he thought it was for carb heating. In any case, it's in an awkward spot for an aftermarket carb/gasket/spacer to cover it. The outer edge of the hole is on the same line as the outer edge of a regular carb gasket and spacer. I was worried it out would burn/blow out. Now I have a 16ga aluminum spacer and 1/16 thick gasket over it, so that should be good enough, at least for a while.

[ArdWrknTrk]

Cory, that's looking good!

The exhaust in your intake is the EGR port.

Ahh OK, that's what I had thought originally, but my brother inlaw said he thought it was for carb heating. In any case, it's in an awkward spot for an aftermarket carb/gasket/spacer to cover it. The outer edge of the hole is on the same line as the outer edge of a regular carb gasket and spacer. I was worried it out would burn/blow out. Now I have a 16ga aluminum spacer and 1/16 thick gasket over it, so that should be good enough, at least for a while.

Those gaskets DO like to blow out/burn through.

If you're not running EGR you might look at running a plug in there, or filling it with high temp steel filled epoxy.

I'm not exactly sure what yours looks like in the bottom, but I put a plug in my 460 manifold when I no longer had to get smogged every year.

I also use the updated pink silicone Ford gasket.

I don't know the number for Windsors though...

[Rembrant]

Those gaskets DO like to blow out/burn through.

If you're not running EGR you might look at running a plug in there, or filling it with high temp steel filled epoxy.

The epoxy idea did cross my mind...

I'll have a look at what products are available before I seal it all up for good.

 

[ArdWrknTrk]

Those gaskets DO like to blow out/burn through.

If you're not running EGR you might look at running a plug in there, or filling it with high temp steel filled epoxy.

The epoxy idea did cross my mind...

I'll have a look at what products are available before I seal it all up for good.

I guess I was just lucky that the 'ear' on a 460 intake has a round port in the bottom that I could tap for a plug.

Don't despair, plenty of head porters pump the thermactor holes directly in the exhaust ports full of high temp silicone to block them off.

All you really need to accomplish is to keep the exhaust from pressurizing that thin area where the gasket seals.

[Gary Lewis]

I guess I was just lucky that the 'ear' on a 460 intake has a round port in the bottom that I could tap for a plug.

Don't despair, plenty of head porters pump the thermactor holes directly in the exhaust ports full of high temp silicone to block them off.

All you really need to accomplish is to keep the exhaust from pressurizing that thin area where the gasket seals.

As the others said, it is looking good, Cory. But I agree with Jim that the port is for EGR and those tend to burn out. But if you have high-temp silicone or epoxy in there it'll keep the heat from the getting to the gasket and it should hold just fine.

[FuzzFace2]

As the others said, it is looking good, Cory. But I agree with Jim that the port is for EGR and those tend to burn out. But if you have high-temp silicone or epoxy in there it'll keep the heat from the getting to the gasket and it should hold just fine.

Yes them pipes look good

Did you block the cross over ports in the head / intake?

I think that is where the EGR port gets the gases from so if they are blocked that should also help let that gasket live as it would not have any gases at it.

Dave ----