Mustang 3.5L Ecoboost engine swap
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GLOCKer (6/22/16)
6/21/16, 08:32 PM
#1503
Cobra Member
Thread Starter
I've been traveling for work lately, as soon as I get back home I'm going to tear that engine apart to see what happened. I'll document everything with pics, I'm looking forward to getting it out and seeing what's inside! I figure by Sunday I'll probably have an answer.
6/23/16, 08:31 PM
#1506
Cobra Member
Thread Starter
So there's a chance that my fuel injected intake manifold was the culprit that hurt my engine. I was thinking of making a custom aluminum intake for my car and was reading a very long thread about how to design it when I came across this.
6/24/16, 08:05 AM
#1507
The statements about high speed air flow having a lot of momentum, to the point of causing fuel distribution issues is very true. Years ago while working with Cosworth in North Hampton England we tried a lot of different injector placements for the second set of injectors on their F1 V8. This was a NA engine with power 6800-10000 RPMs. Even at 6800 RPM the airflow would push the fuel to the rear of the plenum wall. They decided the best placement for the second set of injectors was in the runner stacks facing up, which forces the incoming air to stop the fuel and reverse it's flow. Soon after that they redesigned the complete intake and went to two injectors at the port end, on opposite sides of the port with the secondary ones just a bit higher than the primary ones, both pointed towards the intake valves. The fuel pressure was increased they switched to a better injector nozzle design for atomization. Later still they went to one injector for each intake valve using extended range injectors.
Pretty soon the 2017 Raptor intake will provide some good design clues.
One other consideration is to insure the second set of injectors are "off" well before closing the throttle completely. As the throttle closes it changes the airflow pattern within the plenum and this can also cause distribution problems. I think we would cut secondary fuel as throttle moved from WOT and be "off" at 85% throttle. We monitored throttle position 4000 times a second and calculated throttle position, rate-of-change and direction every 100 readings. Also the throttle return was slightly damped between WOT and 75% to provide the driver with throttle modulation and to prevent abrupt fuel on/off events.
Pretty soon the 2017 Raptor intake will provide some good design clues.
One other consideration is to insure the second set of injectors are "off" well before closing the throttle completely. As the throttle closes it changes the airflow pattern within the plenum and this can also cause distribution problems. I think we would cut secondary fuel as throttle moved from WOT and be "off" at 85% throttle. We monitored throttle position 4000 times a second and calculated throttle position, rate-of-change and direction every 100 readings. Also the throttle return was slightly damped between WOT and 75% to provide the driver with throttle modulation and to prevent abrupt fuel on/off events.
Last edited by walt460; 6/24/16 at 08:23 AM.
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Ecostang (6/24/16)
6/25/16, 08:31 PM
#1511
Cobra Member
Thread Starter
This is the nipple that had to be fixed at the track. I'm going to get rid of the heater core so this nipple will no longer be needed. I'll probably just cap this off, maybe even weld something over the end. I think the repair is fine but I happen to have an extra one of these laying around, I'll probably swap it out. I may sand and expoxy the outside of the new one just for good measure.
6/25/16, 11:27 PM
#1513
Legacy TMS Member
Originally Posted by Ecostang
If any of you guys are on Instagram or Facebook check out my page and follow me on Instagram. Search 3.5ecostang
6/26/16, 09:02 AM
#1515
Cobra Member
Thread Starter
Thanks Patrick, the more followers the better. The dollars needed to finish the ecostang are getting harder to justify to my wife, followers on IG and may Facebook get me better deals on the parts I need 
The conversation I had with the wife when I told her I needed $15k to get the car racing again was an interesting one lol. At least with some discount on parts it looks more like $10k now but I always seems to run over budget.
So anything you guys can do to help me promote this project to the public is very much appreciated
The conversation I had with the wife when I told her I needed $15k to get the car racing again was an interesting one lol. At least with some discount on parts it looks more like $10k now but I always seems to run over budget.
So anything you guys can do to help me promote this project to the public is very much appreciated
6/26/16, 09:08 AM
#1516
Cobra Member
Thread Starter
6/26/16, 09:22 AM
#1517
Cobra Member
Thread Starter
Like I mentioned before I'm going to use an air to air intercooler along with a water to air intercooler to get the coldest entering air temps as possible. I'm also upgrading the turbos to a top mount and I'm going with much larger Borg-Warner 71/63 turbos. This requires all new turbo piping, new intercoolers, and some next exhaust piping to get done. This will be difficult to get done before the next race in bowling green but I'm going to try. I'm sure the car will need to go back to Florida for the tuning once finished.
I found this kit from On3, I'm going to try and buy just the intercooler and most of the turbo piping and use it for my new turbo setup. If that works out it will save me lots of time fabricating those pipes, also I bet their pipes weigh much less than what I used previously. Their price on the entire kit is reasonable, their kit with turbos cost as much as the turbos I'm buying
http://www.on3performance.com/shop/kit1/
I found this kit from On3, I'm going to try and buy just the intercooler and most of the turbo piping and use it for my new turbo setup. If that works out it will save me lots of time fabricating those pipes, also I bet their pipes weigh much less than what I used previously. Their price on the entire kit is reasonable, their kit with turbos cost as much as the turbos I'm buying
http://www.on3performance.com/shop/kit1/
6/26/16, 05:50 PM
#1519
Legacy TMS Member
Originally Posted by Ecostang
Thanks Patrick, the more followers the better. The dollars needed to finish the ecostang are getting harder to justify to my wife, followers on IG and may Facebook get me better deals on the parts I need
The conversation I had with the wife when I told her I needed $15k to get the car racing again was an interesting one lol. At least with some discount on parts it looks more like $10k now but I always seems to run over budget.
So anything you guys can do to help me promote this project to the public is very much appreciated
The conversation I had with the wife when I told her I needed $15k to get the car racing again was an interesting one lol. At least with some discount on parts it looks more like $10k now but I always seems to run over budget.
So anything you guys can do to help me promote this project to the public is very much appreciated
6/26/16, 07:16 PM
#1520
Cobra Member
Thread Starter
Unfortunately for IG, the sponsorships don't really come until you have like 10k, and trust me it's hard to get that many unless you're begging for it (or "purchase followers," in which case you can just hand over your man card now and you've worked so hard at earning it lol).
I should clarify I'm setting the bar pretty low for sponsors lol. What I'm trying to do is generate enough interest in the car to get a decent discount on parts and to get some high level advice on how to build the car. It's fun to me to have people reach out to help with the car, they want to see it succeed too. I can pay for what I need so I'll never sell my soul haha, I just may not can build it as fast as I want to.