In this episode of the Ford 4V V10 Build, we design and 3D print a full-sized intake manifold. Don't forget to stay till the end to get a preview of what's coming in a future episode!
Great work gentlemen, prototype projects have always been my favorite. We used to do this stuff on manual machinery with good results but additional fixtures and tooling required without computers. Your processes and procedures display quality workmanship, I'm a bit older and really love to see you younger artists at work.
After stumbling across this video I went through and watched them all! Incredible project! I can't wait to see more, and this series is criminally under-viewed! I also have a real curiosity for these V10s.
I don't know how I got here on this series but I am so glad I did. You guys definitely have alot of toys at your disposal but that doesn't take away all the wrenching ingenuity and design work you guys are doing. Fantastic stuff!
Just an option, but MFP Australia offers billet reverse alternator brackets for their Ford Falcons which have Ford 5.4 DOHCs. The timing chain cover is the same as a Navigator 5.4 4v
The manifold looks great, but I believe the runners are too short to get velocity. It will make incredible horsepower at high RPM's, but may lack street ability and low end torque.
What is the solution to the dead headed coolant passages that were welded shut? I’m guessing you will have “head cooling mods” on the front and back of each head? Looking forward to seeing how this all comes together.
Basically the "crack pipe" cooling mod often performed on 4v mod motors and factory equipped on 04-05 Aviator 4v heads. They were already known to have some hot spots back there so ford fixed it too.
Hi i'm new to this series since you welded the heads together have you normalised the heads yet and if you haven't please do so this will normalise the grain structure meaning less chance of cracking
@@ethanwild3301 yes by heating it then letting it slowly cool this will make the grain structure throughout an even size, this has 3 advantages. 1). makes the aluminium not soft at the welds (since AL anneals when rapidly cools which as you know AL is a great heat sink) which leads to cracking if force is used. 2). increases its overall compressional strength of the heads so when tightening the heads it evenly distributes the force evenly making them seal to the block better. 3). completely removing the internal stresses not only from the welds but also from the casting of the heads making them an overall stronger set of heads.
What a shame you couldn't find/use Left & Right hand Throttle Bodies. The new design looks ok ?? But, a more direct path would look and possibly flow a little better. I guess a compromise needs to happen if you're trying your best to keep control of the cost. The first manifold design had a more performance look, where as the revised version looks more like an OEM Manifold. As always, you guys did a great job 👍👍
Wouldn’t you be able to put the injectors on the inside of manifold I feel like it’d follow the runners and air going through it more, it’d hide them more clean up the engine bay a bit and for easier installation and removal a sub harness could be made to disconnect the injector harness instead of having to unplug each one individually.
It seems to me the throttle bodies are going to be sending the air… pretty much straight into a wall. It was simpler and… well, straight the first time around. What about the positions of the throttle bodies was bothersome?
The cost of a boss unit in the states, let alone two that would be needed to make it work is big big money. Hed spend less mony doing it in sheet metal but the boss manifold is sweet
@@tturi2 Ebay has no listings in the US for Boss 5.4 manifolds. Zero. Ebay of AU has local pickup listings only. They are very rare and costly in the states.
Won't the air flow from the throttle bodies be kinda vortexed in a way since they now cross each other or is the plan to put a block between them so that that air flow banks to one side or the other? Also, why not just go with one single bigger throttle body?
I am curious as well. I also would like to know about any issues with deleting the balance shaft that was on the one head. I might run two similar heads and flip one to delete it on my motor
We plan to balance the entire rotating assembly, especially with all the goodies we are getting 😈 With regards to the balance shaft, our research leads us to believe it is purely an NVH solution. It would be interesting for someone with a V10 to remove the shaft gear and drive around to see how it responds.
@@biy_buildityourself I believe you are right on it being for NVH. I do plan on removing mine as I have h beam rods and different pistons. So I think the factory balance shaft would be out of wack as my rotating assembly is hopefully a fair amount lighter. I still need to find a local shop that can balance the v10 crank
Love this project. I think the RPM goal is a little lofty if not just an arbitrary number, my 324 Cid DOHC is silly to 7500…. I have been running this engine in a track car for years…. Check my RU-vid for any information. I wish you luck and I am following along to see the final results. Are you going to use the stock crank ?
8k is definitely ambitious, but it’s certainly doable with the proper supporting hardware. This wont be a track car either so if you’ve been running 7500 for years in a track car, that gives us confidence we’ll be okay! Yup, we’re reusing the stock 6.8 crank for this build. There’s no other option for this engine so we’re definitely going to be putting it through its paces 😬
@@biy_buildityourself sorry, i'm late to the party. the forged crank will handle it, but the oddfire rotation and balance shaft are the big question.. looking forward to your results! 👍
Ive seen one setup with bikecarbs where they used the truck manifold, cut the runners off, and reused the flange and coolant crossover so all the hard fab work was made easy.
Why not have the whole thing 3D printed in carbon strand filled 6/6 nylon and actually run the plastic manifold on the motor? I'm sure there's companys with bigger 3D printers that could print the whole thing, or at the least, runners, and plenum that you could join.
Would be cool to have it 3D printed or injection molded! But it would also be really expensive for a one off. Thankfully aluminum is relatively cheap, and we have the ability to machine a lot of the parts so it should be relatively straight forward making the intake 🤞🏽🤞🏽
I disagree with their use of LS Throttle bodies tho, the Stock 2V V10 Computer can run 3V and 4V heads with tuning changes as long as their not using variable cam timing, which it appears they are not, but it can't run 2 electronic throttle bodies that i know of.... over-complicated on that part, which will also mean they have to use an aftermarket computer...
Im telling you right now. Dont print this in PLA. It wont work. ABS at a minimum. MAYBE PETG. Oh....your gonna make if from sheet metal. Did you test the flow of your manifold in solidworks?
