Grey - P100 stage 1

[Grey]

Hi there,
Thought i might start a project thread with my P100 since I'm starting to rebuild it soon.



History
Bought the car around midsummer 2012 from Åland, thats in Finland, since we guys over here didn't get the benefit of buying the P100 because of its carburetter Pinto (catalytic law since 1988). Anyways, the car is a 1992 P100 that have no extras at all, but since it have been on Åland its almost rust free which is great for a good start! 
I imported the car without any problems and it passed inspections without any fuss.


First thing to do
I started to change the steering wheel and seats, so that i could enjoy the ride a little better. :)
Recaro seats


And a Momo steering wheel.


The interior is hideous, so i will go for a really nice Red/Grey GT interior.

Sierra GT interior
The interior i will put in is from a -93 Sierra GT that i bought a couple of months ago. Since its Red/Grey its a little different from the regular interior, and it will match the P100 Red and Grey exterior. :) Not sure how i will do with the seats, but the extras such as power window and heated front window will be installed. It will make the car as new compared to what is there now.
Newer dash.


GT side panels is also really nice.


And the rest.



So, i will do some updates when there is time but here is a glimpse of whats coming.  

[Grey]

With leaps and bounds I am approaching my first checkpoint of the renovation of the interior, but first something else.
I went to the scrapyard and bought me a little tougher rear axle, more exactly a Ford 8.8 " with LSD and 285mm disc brakes. This thing will surely be able to give a little more durable, better gearing (3.73 compared today's 4.6), a bolt circle more normal (114.3 / 5 compared today's 160/5) and also I get LSD in the bargain!    




The note says 3L73 which is basically saying that it is a LSD diff with 3.73 ratio.


The plan is that I'll get it blasted and then build new mounts. While I install this I will install a Sierra GT front end with power steering, because things like luxury is not available at all (it has nothing extra). While new front end goes on I will install Scorpio cosworth hub and 280mm ventilated discs and slam it to the ground.

So, what happened with the old interior. Well, it has been getting it nice and cosy in the garbage and I have started installing power / audio cables and fixed more sound dampening material in it.
I was not self but I had a very good assistant (my girlfriend) who helped me to dismount the interior.


Under the panels it was not pretty. It was realized that someone had not taken so much care of the interior and unfortunately smoked in the car ... very much too!


After a hearty wash everything was nice and neat.


Under the carpets it was nice and clean, in one place the rust had managed to penetrate but it was stopped effectively with anti-rust paint.


Since I have been thinking of using the car a lot, I began to plan for a little audio installation. In a pickup it's not so long distances that you need to run wires and it is also very easy to get it nicely when carpets and interior are gone so it became like this.
Low level cable.


Power ....


... and speakers :)


And this was it.


The brackets where the amp will be, more on that later.


I painted some panels to make it consistent to the rest of the interior so I chose black satin. Results will come.


... and back panels got fabric.


And right now it looks something like this.



Next time it should sit both panels and power amp in place, armed and ready. Hopefully I have time to install the electricity for the power windows and replacing the rest of the interior so it will get a little newer and fresher.
After that it's time to start changing into electric windows!  

Cheers,

[capri v8 driver]

Looking forward to the next updates.

The 8.8 looks like its from a explorer.

[Grey]

Looking forward to the next updates.

The 8.8 looks like its from a explorer.

Yepp, that's correct. It's from a Explorer (pig head is a bit offset). I have been in the thoughts to shorten the left pipe and use the right drive shaft to get it in center but when reading on several forums and talking to people the experience says that it doesn't matter that much. People run with 500BHP+ with the pig head offset so i think i'll just keep it as it is. What do you guys think?

[capri v8 driver]

I use the explorer axle under my capri. only upgrade i made was new shorter axles and replaced the lds plates and spring for heavy duty ones. no problems to report.

The explorer 8.8 axle is the strongest 8.8 you can get. It has ticker tubing, stronger diff, 31 spline inner axles and disk brakes as standaard. All 8.8 are off set.

[Grey]

I use the explorer axle under my capri. only upgrade i made was new shorter axles and replaced the lds plates and spring for heavy duty ones. no problems to report.

The explorer 8.8 axle is the strongest 8.8 you can get. It has ticker tubing, stronger diff, 31 spline inner axles and disk brakes as standaard. All 8.8 are off set.

Ah, i like what i read.  

True, the explorer axle is the strongest of the 8.8ers but it seems that you need to weld the tubes when getting massive power because there have been some drawbacks as follows:
Rather than welding the tubes into the diff housing, the tubes are just held in with pressed-in plugs. These plugs tend to stop doing their job under severe stress, so you really should weld the tubes to the housing with low-hydrogen rod.


Photo Of Tube Welded To Center Section

The axle shafts are held in by C-clips. This requires opening and partially dismantling the differential in order to remove the shafts, and if you brake a shaft there's nothing to hold your wheel onto the axle housing.

All taken from the ranger station, tech library: http://www.therangerstation.com/tech_library/Explorer8_8.html

Anyways, I will run it as it is. 220BHP or even 400BHP won't damage the pressed-in plugs. Above 500BHP I might think of welding the tubes.  

Oh, by the way. I read that the Mustang 8.8er Pig head is in the center. Don't know if this is true and I will not struggle to get one either.  

[capri v8 driver]

Some 8.8 are centered, but then you have 1 short inner axle and 1 long axle.

You can weld the tubes, but you need to check the axle afterwards for straightness. The c clips are not a problem. when one breaks, the disk's still hold the axle in place.

[whiteestate]

Looks like a serious turbo project !
Going to be a good build, nice 

[Grey]

Looks like a serious turbo project !
Going to be a good build, nice 

Well, if the Granny goes the P100 gets a turbo but else I probably need to keep it simple this year.

[Grey]

The installation of the amplifier is approaching the end.
The back piece that I dressed got really neat compared to the std. gray vinyl.


I took an MDF that I could use as an adapter plate to mount the amp a little better...


... and dressed the adapter in black cloth to match the amp.


After that it was time to install the cables. Luckily, there was already a suitable hole in the carpet where the cables were picked out.


And in the end it became like this.



Since I do not have any speaker boxes yet I'll see what I will do and where there is space to build them. The plan is to put something under the chairs but it's a tight spot to fit them at so we will see, the future will tell. The amplifier and the cables are attached and it is easy to install speaker cables when the time comes.  

[Lemon-Ade]

Nice work Grey very tidy mate keep the updates coming.

[Dave]

What just one amp!  

Will be interesting this.

Only modified one I remember seeing is this one.



Its a 2.9 12v 4x4 with an ice install owned by Phil

[Grey]

What just one amp!  

Will be interesting this.

Only modified one I remember seeing is this one.



Its a 2.9 12v 4x4 with an ice install owned by Phil

Haha, yepp. Just one amp. There is space for another one on the other side so maybe in the future. :) 4x100w is a good start.

Nice one. I don't like the wing though otherwise it was very neat.


I'm thinking of going for Titanium Grey (New Mondeo color). What do you guys think about that?

[Grey]

I've been thinking a bit on the rear axle gear ratio. My plan is to mount a ford 8.8" with LSD and std 3.73 gears which is a lift compared to the Atlas 4.70.
So, I made a chart of what I have today, what I would get with the MT75 and then with the 8.8" axle mounted. Right away when I replace the axle you can see a big difference, but for a penny (almost) I can get a Ford Racing 3.08 gears and then it starts to make big difference.




A little comparison of RPM at 110km/h in 5th gear:
Type9_Atlas @ 470 = 3547rpm
MT75_Atlas @ 470 = 3591rpm
MT75_8.8 @ 373 = 2849rpm
MT75_8.8 @ 308 = 2349rpm

Above you can clearly see how much difference it really makes to change the gear ratio in the rear axle. Below is the top speed at 6500rpm in 5th gear
Type9_Atlas @ 470 = 202km/h
MT75_Atlas @ 470 = 199km/h
MT75_8.8 @ 373 = 251km/h
MT75_8.8 @ 308 = 304km/h

With the right setup the car is good for 300 km/h (183 mph). Scary!   (Nothing compared to Daves monster Sierra though. He max out at 340 km/h, 207 mph!)

Here is a chart so you can easily compare km/h and RPM on 5th gear.


Initially it will be to run the 8.8 "and 3.73 but a switch to 3.08 is guaranteed...

[Dave]

But mine is geared firstly for MPG mate is that really what you want?

Not sure how this thing will launch, don't think you will get much weight transfer so it won't squat.

You might have to add some weight to it so it grips.

Will be a great drifter I think


Found another for you!

I doubt very much it makes much more than 400bhp by the way.

[Grey]

But mine is geared firstly for MPG mate is that really what you want?

Not sure how this thing will launch, don't think you will get much weight transfer so it won't squat.

You might have to add some weight to it so it grips.

Will be a great drifter I think


Found another for you!

http://www.youtube.com/watch?v=m4pOK9OfwmQ

I doubt very much it makes much more than 400bhp by the way.

Plan is to go for long runs with it so a low MPG is also important for me. If i can use it and go 10s down the strip and also drift with it, it's just a bonus. You can always get more power. :)

Thanks for the link, nice P100.
About the Storm engine, why not more than 400bhp?

[Dave]

Because to get over 350bhp with what looks like a STD plenum is hard to do & it gets harder the further you push.

Generally their engines are hyped up & fall short of whats claimed.

Must admit however these new conversions look & read pretty good but not with the STD plenum.

[Grey]

Because to get over 350bhp with what looks like a STD plenum is hard to do & it gets harder the further you push.

Generally their engines are hyped up & fall short of whats claimed.

Must admit however these new conversions look & read pretty good but not with the STD plenum.

Hmm, interesting thought.
Is the std plenum that bad? I reckon if you can get 220bhp+ out of the std plenum with just easy upgrades to air in and out, on 1 bar (14psi) you should get 440bhp without any fuss! As i can remember we got a  capri here in Sweden about 10 years ago that had twin turbo boosted with 1.2bar and they run low 11 and for that you need atleast 450bhp. They got a std plenum.

Isn't the discussion about the plenum always worse than it sounds? I have heard from a lot of people that the std 12v 29er plenum is crap and it flows no good. Apparently it do flow good since i run it without any modifications. :)

I can think that they can boost the numbers though since they want reliability to their engines it's easier to just boost up while tuning it and then lower the boost when it is put in a customer car. Installation looks really good though.

[Grey]

So, here is an fast update.

I have been working in transferring the Sierra -93 GT interior to my P100, and so far it have worked great!
I have also mounted the Scorpio side panels for the seats so now you cant see the seat frame mounts. (see first pic)
Half is done and it looks like this.




I'm now waiting for some cables that I ordered. When they come i can complete the harness for the central locking and electric windows. When working with that i also fitted the ECU and relay mounting. Since it was a pinto carburetter, i didn't have that. Now i will need it for several things, such as relays and fuses for the electric windows, central locking and the Megasquirt I'm going to mount when i drop in the cossie engine.
The mount.


On the left you can see the power cable to the amp.  


Ah well, more updates later on.

[capri v8 driver]

Because to get over 350bhp with what looks like a STD plenum is hard to do & it gets harder the further you push.

Generally their engines are hyped up & fall short of whats claimed.

Must admit however these new conversions look & read pretty good but not with the STD plenum.

Hmm, interesting thought.
Is the std plenum that bad? I reckon if you can get 220bhp+ out of the std plenum with just easy upgrades to air in and out, on 1 bar (14psi) you should get 440bhp without any fuss! As i can remember we got a  capri here in Sweden about 10 years ago that had twin turbo boosted with 1.2bar and they run low 11 and for that you need atleast 450bhp. They got a std plenum.

I read a artical somewhere on the net (can't find it anymore) about a pressure test on a boa 24v whit a turbo whit the stock intake, they set the boost pressure at 10 psi, measured on the trottle body, when they checked the pressure at the end off the intake (close to the intake port at the head) there was only 7 psi left. Thats a 30% lose of pressure. And the losses where even greater whit more boost pressure. If you lose so much whit boost pressure, than you can only imaging how much is lost when the 24v sucks air trough the boa intake on a n/a 24v.

I did build a boa with a adaptor plate and a bob intake and i test whit a g tech pro and set the weight at 1400kg, whit the stock intake (whit bob cams) The result's where 141.5 hp at 5872 rpm and 177.5 nm at 4386 rpm at the wheels (i took the average from 4 runs)

Whit the bob intake (the average from 5 test) is 152.7 hp 5947 rpm and 196 nm at 4476 rpm.

Thats a 11 hp and 19 nm increase over the stock boa intake, at the wheels.



http://www.fordpower.org.uk/forum2/index.php/topic,747.0.html

[Grey]

Because to get over 350bhp with what looks like a STD plenum is hard to do & it gets harder the further you push.

Generally their engines are hyped up & fall short of whats claimed.

Must admit however these new conversions look & read pretty good but not with the STD plenum.

Hmm, interesting thought.
Is the std plenum that bad? I reckon if you can get 220bhp+ out of the std plenum with just easy upgrades to air in and out, on 1 bar (14psi) you should get 440bhp without any fuss! As i can remember we got a  capri here in Sweden about 10 years ago that had twin turbo boosted with 1.2bar and they run low 11 and for that you need atleast 450bhp. They got a std plenum.

I read a artical somewhere on the net (can't find it anymore) about a pressure test on a boa 24v whit a turbo whit the stock intake, they set the boost pressure at 10 psi, measured on the trottle body, when they checked the pressure at the end off the intake (close to the intake port at the head) there was only 7 psi left. Thats a 30% lose of pressure. And the losses where even greater whit more boost pressure. If you lose so much whit boost pressure, than you can only imaging how much is lost when the 24v sucks air trough the boa intake on a n/a 24v.

I did build a boa with a adaptor plate and a bob intake and i test whit a g tech pro and set the weight at 1400kg, whit the stock intake (whit bob cams) The result's where 141.5 hp at 5872 rpm and 177.5 nm at 4386 rpm at the wheels (i took the average from 4 runs)

Whit the bob intake (the average from 5 test) is 152.7 hp 5947 rpm and 196 nm at 4476 rpm.

Thats a 11 hp and 19 nm increase over the stock boa intake, at the wheels.



http://www.fordpower.org.uk/forum2/index.php/topic,747.0.html

Interesting facts.
Guess there is some HP to gain if you build your own intake, i have looked into it and further on i will start a project to build a plenum for the 2.9 BOA.
My thoughts right now is that it will be three different setups.
1. N/A version with intake funnels and plenum (2 parts).
2. Turbo version with intake funnels, water cooled intercooler and plenum (3 parts).
3. Supercharger version with intake funnels, water cooled intercooler and mounting bracket for a Supercharger (Eaton M122 for a start since i have one laying around and it's by far the best version of the Eaton M-models. 2-parts).

[Grey]

When doing anything serious it always takes longer than you think, it's really nothing strange about it. The strange thing is that you never learn that it takes longer than you thought. :)

This weekend's goal was to finish up to just mount the dashboard, ie fix the electricity that goes behind it, so on Saturday morning I sat at the kitchen table and began to fix the wiring harness for the electric windows and central locking.

It all began with one big mess of stuff.


All joints were soldered ...


... and all contacts even so.


Harness was wound ...


... and a fuse box mounted. One fuse for central locking and one for the electric windows


Eventually, it became something like this.


To this I added a remote to the central locking system, so now I can theoretically open and lock the doors of about one kilometer, provided that I put the antenna on the receiver. :) I'll try and see how far it goes without antenna, but the experience tells me that it should be around 100m, not that i know when i will use that feature though.  


The mount of the relays and data box also became a mount of the fuses and the receiver for the remote central lock.



The next step was to fix the doors. I mounted electric windows, central locking and even a pair of Sony Xplode 4 "speakers, mostly to have something to listen with until I find some better.
When everything was ready I did a test and everything worked instantly. 'd Be damn if it did not, is a very simple wiring diagram. :)

The interior was installed and what a difference it is! Now that it is nearing the end, you will notice how much difference it really makes to have a nicer interior.
Before


After



The next step in the chain will be to install the dash and then go and do the annual inspection (MOT).  

[Dave]

Nice one Grey, interior looks very homely 


As for the BOA Plenum.

It was designed for good mid-range, good idle & a nice flat torque curve making it particularly suitable for an automatic gearbox.
That is the brief from Ford given at the press at launch.
If you look inside there is two area's where they have restricted the air flow slightly to create resonance charging that must be tuned for mid range.

The side plates are stuck on, you can remove them & space them further away from the trumpets to increase flow but will also reduce resonance.



The main problem is after the throttle the air goes through a maze. You can flow that the best you can.



Other than them two area's the rest is good!




Turbo Technics simply worked on the STD plenum for the lower powered engines, you can see they welded the sides back on.



For 500bhp plus they did their own design using 12 injectors, 6 of which fired into the top of trumpets to help with charge cooling.



Another easier example to copy.




The 12v plenum is just an old design, it flows O.K but uses no modern ram effect cylinder charging like modern plenums like the 24v's.

[Grey]

Nice one Grey, interior looks very homely 


As for the BOA Plenum.

It was designed for good mid-range, good idle & a nice flat torque curve making it particularly suitable for an automatic gearbox.
That is the brief from Ford given at the press at launch.
If you look inside there is two area's where they have restricted the air flow slightly to create resonance charging that must be tuned for mid range.

The side plates are stuck on, you can remove them & space them further away from the trumpets to increase flow but will also reduce resonance.



The main problem is after the throttle the air goes through a maze. You can flow that the best you can.



Other than them two area's the rest is good!




Turbo Technics simply worked on the STD plenum for the lower powered engines, you can see they welded the sides back on.



For 500bhp plus they did their own design using 12 injectors, 6 of which fired into the top of trumpets to help with charge cooling.



Another easier example to copy.




The 12v plenum is just an old design, it flows O.K but uses no modern ram effect cylinder charging like modern plenums like the 24v's.

Thanks mate! Feels really good now when it is nice and clean.

Ah, i see. Well, I will probably build my own when the time comes, but to run with 220bhp on std plenum is pretty OK in a std setup.

[Grey]

Finally the interior is done!
http://www.youtube.com/embed/V4oUG18RNhI (Sorry for the loud metal in the background.   Need some nice music when working on the car)





Now i just have to fix a seal for the break reducer. Seems to be tough to get a repair kit for it so I guess I will have to make something special.


Feels really good that the interior is finally done. Now i can just leave that behind and go for a run. Just have to wait until the weather gets better. Snow storm here right now...

[dr knockers]

I use the explorer axle under my capri. only upgrade i made was new shorter axles and replaced the lds plates and spring for heavy duty ones. no problems to report.

The explorer 8.8 axle is the strongest 8.8 you can get. It has ticker tubing, stronger diff, 31 spline inner axles and disk brakes as standaard. All 8.8 are off set.

Where did u get the heavy duty lsd plates and springs please?

[capri v8 driver]

I use the explorer axle under my capri. only upgrade i made was new shorter axles and replaced the lds plates and spring for heavy duty ones. no problems to report.

The explorer 8.8 axle is the strongest 8.8 you can get. It has ticker tubing, stronger diff, 31 spline inner axles and disk brakes as standaard. All 8.8 are off set.

Where did u get the heavy duty lsd plates and springs please?

Summit Racing

31 spline http://www.summitracing.com/parts/fms-m-4700-c/overview/

28spline http://www.summitracing.com/parts/fms-m-4700-b/overview/

Here you can see what you need to do: http://www.fordtruckclub.net/forum/showthread.php?t=7117 or beter: http://forums.corral.net/forums/94-95-tech/541230-8-8-trac-lok-rebuild-f150-s-spring.html

You don't need a stronger spring.

[Grey]

I use the explorer axle under my capri. only upgrade i made was new shorter axles and replaced the lds plates and spring for heavy duty ones. no problems to report.

The explorer 8.8 axle is the strongest 8.8 you can get. It has ticker tubing, stronger diff, 31 spline inner axles and disk brakes as standaard. All 8.8 are off set.

Where did u get the heavy duty lsd plates and springs please?

Summit Racing

31 spline http://www.summitracing.com/parts/fms-m-4700-c/overview/

28spline http://www.summitracing.com/parts/fms-m-4700-b/overview/

Here you can see what you need to do: http://www.fordtruckclub.net/forum/showthread.php?t=7117 or beter: http://forums.corral.net/forums/94-95-tech/541230-8-8-trac-lok-rebuild-f150-s-spring.html

You don't need a stronger spring.

Really good links, will be of good use when i upgrade the engine with more power and the axle gear ratio to 3,08. I think i did the right choice to go for a 8.8" from a explorer -97 with discs. 

[dr knockers]

That mustang forum link is very handy.... I picked up one of these already shorten for the van, it is massive compared to an ford english or even atlas....... They certainly look tonk enough!

[Grey]

So, it's been a while since the last update.
Well, I got through MOT and had a vote on the skogenracing site, what front i should use.
This one won!



Also i have discussed the zetec RWD water pipe and have not found any that goes on the intake side which would make my life much easier. 
All of the RWD conversions goes on the exhaust side and that is not interesting at all so I will make my own adapter plate and put it on the intake side instead.

By the way, the plan at the moment is to drop in a Zetec-R black top and add a turbo + 10 psi. Should get around 225 hp with that setup. 
As long as the engine likes boost, maybe I'll push it to 15 psi and 270 bhp.