[9986paulk]

Well I had some free time the last couple days and have been doing some work on the car. I'm selling the windstar to free up some money and because that's the easiest way to run the piping to the TB. Here are some pics for anyone who might care. All I have to do now is cut the piece of aluminum plate for the top and put a few screws in it.

Just the porting. I didn't make them terrible smooth because apparently you're not supposed to. And a also didn't have any sanding cartridges at the moment.


Using the carbide cutter in a drill press to do the actual post removal, still leaving a flat finish for the manifold bolts inside.


This is what it looked like after I ground the posts down.


Then I removed the upper hollow sections of the posts with a hole saw in the drill press.


Here's what the view from the throttle body opening looked like when done. It looks as if it freed up a little less than 1/3 of the cross sectional area, which I didn't remember to take a pic of before for reference.


And here's where I'm going to cut the plate, seal it, and screw it down.


Here it is, done but without screws lol

[SlowSix]

I'm confused by what the posts are...someone explain?

[walt1120]

what about the rest? are you doin a full cut & weld job?

[9986paulk]

If you look at your stock upper, you have 2 posts that go down directly through where the air flows right after the TB. It was designed that way to be easy to manufacture and to bolt it down easily. And plus it was for a V6...lol

[9986paulk]

I'm thinking about doing the cut/weld since it's only like 2 more cut pieces and I have a welder. I may not though since I'm just running it for this year pretty much, then doing the swap. I'm just not sure it would be worth it. I could just up the boost a tuny bit and be exactly the same.

[SlowSix]

Originally Posted by 9986paulk If you look at your stock upper, you have 2 posts that go down directly through where the air flows right after the TB. It was designed that way to be easy to manufacture and to bolt it down easily. And plus it was for a V6...lol

Gotcha. I never really looked at the stock upper all that much.

[walt1120]

Originally Posted by 9986paulk I'm thinking about doing the cut/weld since it's only like 2 more cut pieces and I have a welder. I may not though since I'm just running it for this year pretty much, then doing the swap. I'm just not sure it would be worth it. I could just up the boost a tuny bit and be exactly the same.

i havent been on here in a while, what swap are you doing next year?

[9986paulk]

Well right now I'm doing TT on the 6 which should be done in the next week.
Next year I'm swapping in a built 4.6 and building another TT kit for that using the same turbos. And I'd like to use a manula tranny, but as far as cost vs. strength idk for sure at this point. Just something different.

[walt1120]

sounds good man, 4v im assuming? if you do go manual go at least t-56. a lightly built 4r70w is pretty bulletproof though

[9986paulk]

Yeah that's the thing there's like a $2k difference between a t-56 and the auto. But no, it's a 2v. I thought about it, but since I'm forging it and running FI it seemed like it would just cost more to get where I want with the extra cost of a 4v. Even though they do sound amazing. But I think with cams this will sound pretty good too, even with the turbos.

[walt1120]

Originally Posted by 9986paulk Yeah that's the thing there's like a $2k difference between a t-56 and the auto. But no, it's a 2v. I thought about it, but since I'm forging it and running FI it seemed like it would just cost more to get where I want with the extra cost of a 4v. Even though they do sound amazing. But I think with cams this will sound pretty good too, even with the turbos.

yeah you can just turn up the boost a little to make up for it not being a 4v lol.

[southfour!]

how dare you hack up my upper intake


But seriously, why not just go with the windstar if you have a welder to modify the cold side?

[SlowSix]

Originally Posted by southfour how dare you hack up my upper intake But seriously, why not just go with the windstar if you have a welder to modify the cold side?

I'm assuming its easier to route the piping for the coldside with the stock upper rather than the windstar

[southfour!]

Originally Posted by 01SilverSixer I'm assuming its easier to route the piping for the coldside with the stock upper rather than the windstar

Well it is but I would think that it would be about as much work as a cut n weld job.

[9986paulk]

Well this took me about 4 hours to do the entire thing. But the way I looked at it was I'll be able to get some money back out of this when I sell the engine at the end of the year and put the 4.6 in. An plus, to do the windstar with it, I would've had to move the power steering lines at minimum and maybe the coolant tank because now I have turbo piping to run into where I routed the piping before.

[2000stallion]

So, you took out the post to increase air flow? Never heard of that or even looked that close at the upper intake before...What gains are you expecting from that?

[southfour!]

Originally Posted by 2000stallion So, you took out the post to increase air flow? Never heard of that or even looked that close at the upper intake before...What gains are you expecting from that?

Some people say that a full cut n weld upper intake is one of the best options. There is a guy on v6p who cut his to pieces and pretty much doubled the size of the inside.

When I get home from school I will find the link

[walt1120]

id like to see a dyno test between a cut/weld stock vs windstar.

[w00v6]

I'd like to see that dyno test, too.

[ESG-642T]

Originally Posted by walt1120 id like to see a dyno test between a cut/weld stock vs windstar.

You'll never see that because anybody who is doing a cut and weld is prob doing it on a boosted motor.