4.6L 3V Build

[tmcolegr]

I took delivery of my Windveil Blue S197 GT Coupe in Jan. 05. Vehicle is equipped with a 5R55S automatic transmission and currently has 9,800 miles on it. My original goals, from the day I purchased the vehicle, were to (1) have a reliable, (2) driver friendly, (3) 500 – 525 SAE RWHP daily driver. So fast-forward a little over 4 ½ years. I have installed just about every bolt on mod possible that did not require modifying the factory long block. Although I have reached goals # 2 & 3 (drivability and 500 -525 RWHP), I wouldn’t consider the factory long block reliable long term at the current HP level. So plans this winter are to upgrade to a forged 298 CID rotating assembly using the stock 4.6L 3V aluminum block and heads. I do not plan on increasing RWHP above 525 – 550 max. as I do not believe the 5R55S is capable of reliably performing above that HP level. I also do not plan on any trips to the track – street duty only. I anticipate this venture taking 6 months as I will personally be performing all labor to R&I and D&A the engine, to include all required machine work of the original block – torque plate boring & honing, file fitting rings, etc. Planned mods will include:

• JDM 298 CID Forged Rotating Assembly
  • Kellogg Forged Steel 3.750” Stroker Crankshaft – 8 Bolt
  • Manley H Beam 4340 Rods w/ARP Rod Bolts
  • Manley Forged Aluminum Pistons w/Rings - .020” Oversize
  • ARP 3V Main Studs
  • Federal Mogul Rod & Main Bearings – std. Size
  • GT 500 O-Ringed Oil Pump
• FRPP 8 Bolt Flex Plate – Modified for use with 5R55S Auto Trans.
• ARP 3V Head Studs, Harmonic Balancer Bolt & Flex Plate Bolts
• Comp Cams XFI VSR Stage 2 Blower Cams w/high load valve springs and steel retainers
• OEM Head Gaskets and One-Time use Torque-to-Yield Hardware (cross mounted main cap bolts & cam phaser bolts)
• TCI Billet Input Shaft
• JDM Custom Tune - 93 Octane Pump Gas

These new mods will compliment my existing mods:

• Ford Racing Performance Parts:
  • 4.10 Gears
  • Cam/Valve Covers – Powdercoated Black
  • Borla “Stinger” Axle Back Exhaust
• Kooks:
  • Long Tube Headers w/Stage 8 Locking Bolts
  • Off Road X-Pipe
• Autolite: HT0 Spark Plugs (Gapped @ .030”)
• C&L: “Racer” Intake Tube w/Bump Hose & Clamps
• JDM Engineering:
  • Saleen 2.87” (14.5 PSI) Supercharger Drive Pulley
  • Gates K061073 Micro-V Belt
  • Saleen Series VI Supercharger
  • Saleen GT 500 Dual Fuel Pump, FPDM & Harness
  • 03-04 Cobra MAF Sensor Conversion/Pigtail Harness
  • Cold Air Intake w/K&N Filter
  • Vacuum Upgrade Kit
  • Lowered Prothane “Bullet” Engine Mounts
  • OEM GT 500 Throttle Body, Spacer, Bump Hose & Clamps
  • Intercooler Relay Kit w/switch
  • Aluminum Transmission Overflow/Catch Can
• SCT: Excalibrator 2 Tuner
• Granatelli BA-2400 MAF Housing w/Sensor
• Sieman Deka 60 lb./hr. Injectors w/conversion harnesses
• Canton Aluminum Coolant Reservoir
• Afco GT 500 Pro-Series Dual Pass Heat Exchanger
• Canton Aluminum Power Steering Reservoir
• Spal: (2) 5.2” Heat Exchanger Fans w/Relay & Temp. Switch
• Be Cool: Aluminum Radiator
• TCI:
  • StreetFighter Torque Converter (3,000 Stall)**
  • StreetFighter Ratchet Shifter w/B&M Brushed Aluminum Shift Handle
• PMP: Line Locks w/Jeg’s Solenoids
• MSD: Launch Master 2 Step
• Meziere Enterprises: Electric H2O Pump w/V10 (5.5”) Idler Pulley & Relay Kit
• Thump RRR Racing: Billet Aluminum Belt Tensioner w/76 mm Stamped Steel Idler Pulley
• Metco Motorsports Solutions: Drive Shaft Safety Loops – Front & Rear
• BF Goodrich:
  • g-Force T/A KDW NT 255/45ZR18 Tires – 769 RPM (27.0”) @ 45 MPH - Front
  • g-Force T/A KDW NT 285/40ZR18 Tires – 771 RPM (27.0”) @ 45 MPH - Rear
• Strange Engineering: Adjustable Rear Shocks
• Steeda:
  • Billet Aluminum Lower Control Arms – Rear
  • Billet Aluminum Sway Bar Mounts – Front
  • Competition End Links – Front
  • Control Arm Bushing Kit - Front
  • Magnetic Engine Oil Drain Plug
• LPW Racing Products: Extra Low Profile Ultra-Pro Cast Aluminum Differential Cover
• BMR Fabrication:
  • LCA Relocation Brackets - Powdercoated Black Hammertone
  • A-Arm Support Brace - Powdercoated Black Hammertone
  • Upper Panhard Rod Support - Powdercoated Black Hammertone
  • Adjustable Panhard Rod w/Poly Bushings - Powdercoated Black Hammertone
  • Progressive Lowering Springs (1.25” Front /1.50” Rear) – BMR Red
  • Adjustable UCA w/Poly Bushing - Powdercoated Black Hammertone
  • HD Sway Bars – Front & Rear - Powdercoated Black Hammertone
  • Rear Sway Bar Billet Aluminum End Links
  • HD Boxed Sub Frame Connectors - Powdercoated Black Hammertone
  • Camber Adjusting Bolts
• Ford:
  • GT 500 Strut Tower Brace – Powdercoated Black Hammertone
  • GT 500 14” Front Brake Kit
• Hawk: HPS Brake Pads – Rear
• CHE Performance Products: Axle Brace

**TCI Torque Converter will most likely be replaced with a PI 3,000 RPM Stall Multi-Disc Torque Converter

 

[NastyStang113]

Sounds great but why don't you head over to VMP to get a dyno tune?

 

[tmcolegr]

Justin is a fine tuner and his dyno is first class. As a matter of fact, I am currently running his SCT tunes in my wife's Saleen S/C'd 06 GT and my 08 F150 - both with excellent results.

However, for this particular build I will be using JDM.

 

[NastyStang113]

I think I understand. It sounds like a great build. Who's doing the machine work? I need to find a good machine shop around here ...

 

[tmcolegr]

Who's doing the machine work? I need to find a good machine shop around here ...

Good luck on that!!

As mentioned in my original post:

I will personally be performing all labor to R&I and D&A the engine, to include all required machine work of the original block – boring, torque plate honing, file fitting rings, etc.

I could not find a machine shop in the entire Tampa Bay area that I felt comfortable with. Therefore I will be doing all machine work myself.

 

[ZmanM3]

Sounds like a sweet build.

 

[saleen07gt]

That's a pretty serious list you've got here for a car that won't see any track duty. Those poor BFGs don't stand a chance. As far as machine shops here in the Tampa Bay area I can think of 2 that have excellent reps. but I'm not sure about their modular experience.

 

[tmcolegr]

Yes I agree there are some excellent machine shops in the Tampa Bay area. But when I asked specific questions about our 4.6L 3V engines, they didn't have the right answers.

 

[saleen07gt]

Yes I agree there are some excellent machine shops in the Tampa Bay area. But when I asked specific questions about our 4.6L 3V engines, they didn't have the right answers.

Did you speak with Southern Style Racing Engines or Chris Thompson Racing engines ?

 

[one eyed willy]

if you need any help,pm me,ill come help you yank it out or what ever else you need. as far as machine shop you could try dave isley,i have heard good things thats about all they do is mod motors from what i have heard.hes in the brandon/tampa area.

we should get together some time, we do alot of local meets,just a few guys hangin out on a friday night or something.

 

[chad05gt]

K, now... where is nearest track...

 

[MexGT]

Paul Meister @ Torq is also in Florida, BBR and so on, theres several very good tuners there !

 

[tmcolegr]

Did you speak with Southern Style Racing Engines or Chris Thompson Racing engines ?

as far as machine shop you could try dave isley,i have heard good things thats about all they do is mod motors from what i have heard.hes in the brandon/tampa area.

Paul Meister @ Torq is also in Florida, BBR and so on, theres several very good tuners there!

Thank you very much for the recommendations

 

[kenneth]

I woould think with all those upgrades it would put you iver the 525-550 range.
or are you already running the 2.87 pulley on the stock long block?

 

[94tbird]

You should pick up a Thump_RRR Racing 2.95" Saleen S/C Pulley. They look badass

 

[US-1]

....to include all required machine work of the original block – boring, torque plate honing, file fitting rings, etc.

Not sure if it is just how you listed this but the plates should be on the block during boring as well as honing. Good luck with the build. Good to see someone with the capability to do their own machine work.

 

[tmcolegr]

Not sure if it is just how you listed this but the plates should be on the block during boring as well as honing. Good luck with the build. Good to see someone with the capability to do their own machine work.

Thank you for bringing that typo to my attention. I have edited my original post to reflect that change.

I received my BHJ R model torque plate just last week. By the way, I will be using a Rottler F88E Boremaster for the block machining and a Sunnen CV616 Vertical Honing Machine for block prep.

 

[tmcolegr]

I would think with all those upgrades it would put you over the 525-550 range.
or are you already running the 2.87 pulley on the stock long block?

I am already running a 2.87" pulley. I know this sounds strange but I intentionally don't want to run over 525 - 550 SAE RWHP (roughly 615 FWHP) as I have no intentions of upgrading my 5R55S to a 4R70W. I also want to run 93 octane pump gas.

 

[US-1]

Thank you for bringing that typo to my attention. I have edited my original post to reflect that change.

I received my BHJ R model torque plate just last week. By the way, I will be using a Rottler F88E Boremaster for the block machining and a Sunnen CV616 Vertical Honing Machine for block prep.

The BHJ unit is the one I have as well. Those two machines aren't too bad either! Good luck!

 

[tmcolegr]

I have finally received all of my parts and tooling with the exception of the JDM forged rotating group, which I will be ordering later this month or early next month at the latest. I have also opted to go with Comp Cams phaser limiters, and an ATI Std. diameter 6 rib balancer.