Project COBRA'33 Project COBRA'33
THE ENGINE:
Make: Ford Motor Company
Size: 4.6L DOHC 4V
HP: 400-425 stock
The engine shown above is a picture of the actual engine to be used in Project COBRA'33. It was bought new on 10-01-06 from Engine Exchange. This particular engine makes the perfect platform for a true performance engine, it is built with a full forged bottom end using Manley racing products. The block utilizes a four bolt main cap with an additional two cross-bolts per main cap on the sides, making it extremely stout and reliable.
FUEL RAILS
In it's factory form, the sequential port fuel injection system utilizes a Non-return or return-less type arrangement, this will be changed to a Return type system. For Project COBRA'33, We will change out the Fuel Rails for a larger set of Aeromotive Fuel Rails, part number 14120. We need these for the Return type fuel system and the larger Fuel Rails will also help accommodate the larger injectors we will be running. www.aeromotiveinc.com . Several of the pieces for the fuel system were purchased at www.jegs.com .
FUEL INJECTORS
The stock 39lb/hr Fuel Injectors will be replaced by bigger 42lb/hr Fuel Injectors form Ford Racing Performance Parts, part number M-9593-F302. These new Fuel Injectors are necessary to reach our goal of 600+HP, the new ones are some 7% larger then the stock 39lb/hr injectors. Since Air and Fuel are usually the limiting factors in horsepower, the larger Fuel Injectors were needed to attain or projected horsepower ratings. While this isn't that large of a change, together with the larger size we will also adjust our fuel pressure up to make more power. Regularly the fuel pressure is set at 39-41 psi, we will run more then stock fuel pressure to bring us to the power level we need. Remember, fuel flow is based on size and pressure, so by increasing both, we can make a significant amount more power.
FUEL PRESSURE REGULATOR
In the stock configuration, you will remember that the engine utilized a Non-return type fuel injection system, the fuel pressure was regulated by the Engine Management System, there it simply speed-up or slowed down the fuel pumps. In a Return type fuel system, like the one we will be running on Project COBRA '33, the fuel pumps operate at full power all the time and a Fuel Pressure Regulator is used to maintain fuel pressure to the fuel injectors. Obviously with the fuel pumps running full blast all the time, there is going to be way to much fuel available most of the time. To remedy this the Fuel Pressure Regulator uses a By-Pass to re-direct the unused fuel back to the fuel tank, through the return fuel lines. This allows for even regulation, with the ability to easily adjust during peak fuel demand times. Again we choose to go with Aeromotive and their A1000 Fuel Regulator part number 13101.
FUEL TANK
The Fuel Tank in Project COBRA ‘33 had to be replaced, while it was still in-tacked and at least visibly OK, It was just to contaminated to re-use. Also the tank was not set-up for use with a return style fuel injection system. We purchased the new tank from Tanks,Inc, and while it’s true that it to was not fully set-up for our style of fuel injection, the repairs necessary to make it complete were fairly easy to perform. Tank,Inc (www.tanksinc.com) has a kit that contains all the necessary parts to properly set-up our Fuel Tank so it will not only allow us to use the return type fuel system, but also allow us to install the proper in-tank fuel pump and it’s supporting parts and pieces.
FUEL FILTER
Every fuel system needs a Fuel Filter, and ours is no different. What is different is that we have a performance fuel system that operates at high pressure and with high peek demands. We chose a Aeromotive high performance Fuel Filter. Part Number 12308, It has the pressure and flow characteristics needed and the easy to change filter I wanted.
FUEL SUPPLY AND RETURN LINES
The single Fuel Line that came on Project COBRA ‘33 was severely damaged and under sized. There is a huge difference between a engine that makes 60-80HP and one like ours that makes 600HP. We will run new Fuel Lines and they will both be made of aluminum. The feed line will be ½" in diameter, and will transition to a AN-8 flexible Fuel Line at the engine. The Return Fuel Line will be a 3/8" line and will transition to a AN-6 line at the engine. The two lines will be color coded as well, the Supply Line will be RED and the Return Line BLUE. The lines and all fittings came from Summit Racing, www.summitracing.com
FUEL PRESSURE GAGES
There will be several Fuel Pressure Gages monitoring the engine fuel system. Fuel Pressure is very important, it not only allows the engine to make maximum horsepower when needed, but it controls almost every flaccid of proper engine operation. Without consistent and proper Fuel Pressure, the engine will not only run bad, it could very well cause the engine to burn up because of low engine fuel pressure. If the heart of an engine is it's cam, then the engine oil would be it's life blood and the fuel system would be it's energy. Every engine tuner fears low fuel pressure, it will destroy an engine in the matter of seconds.
Project COBRA '33 will have several Fuel Pressure Gages, Three alone in the engine compartment, and a Fuel Pressure Gauge in the dash panel. Our engine tuning system from Innovate Motor-sports will also monitor the engine Fuel Pressure. I use filled Fuel Pressure Gages (glycerin) for the ones mounted directly to the fuel lines, Summit part number 800260. And the inside Fuel Pressure Gauge will be a electric one from Dakota Digital (www.dakotadigit.com) .
FUEL PUMP
The Fuel Pump will be a Walbro 255l/hr Fuel Pump. We bought it from Tank,Inc. when we purchased the conversion kit for the fuel tank. It has the ability to support well over 800 HP, so were covered.
OILING SYSTEM
Our engine came factory with a impressive internal oiling system, so we don't have to modify or change out the pump, but what we will change is the Oil Pan and Wind-age Tray. For those pieces we went to the leader in 4.6L oiling systems, Canton Oil Pans.
MAF INTAKE AIR SYSTEM
We purchased a complete C&L Performance 95mm MAF System from Sean Hy-land Motor-sports, www.seanhylandmotorsport.com . The system consist of a new 95mm aluminum housing for a new Mass Air Flow Meter, a new Inlet tube and High Flow Dry Filter. According to reports it's suppose to be a wicked system, my only worry is that the inlet tube will not work in the very cramped confines of Project COBRA '33.
MASS AIR FLOW SENSOR
Our engine did not come with a Mass Air Flow Sensor, so we purchased one from Sean Hy-land Motor-sports. It is already calibrated to work with a 42lb/hr injectors, which is what we switched to.
MANIFOLD ABSOLUTE PRESSURE SENSOR
We needed and Manifold Absolute Pressure Sensor (MAP) for our engine since it didn't come with one. We went to Sean Hy-land Motor-sports again and bought a 2-bar, which is good for engine making up to 20lbs boost.
THROTTLE BODY
We will run the Accufab (1696cfm) Single Blade "Big Oval" Throttle Body Kit, Part# ACC-CTB2003P. It is quite a bit larger then the stock Throttle Body, and is polished to a beautiful shine.
The new unit will Flows almost 1700 cfm, vs 1089 for the stock Throttle Body, that a little over a 50% improvement! New inlet casting straightens the path for airflow. Gain up to 25 hp 6400 rpm.
MASS AIR METER
For Project COBRA'33 we will switch out the stock Mass Air Meter and replace it with a much larger one from a Ford Lightning Pickup. The new Mass Air Meter is a Ford 90mm unit that is already calibrated for 42lb/hr injectors, like the ones we will be running.
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part # M-12579-L54 SUPERCHARGER PULLEY
MOTOBLUE™ "QC" Single STREET/STRIP Pulley Kit (polished) We will replace the stock Supercharger Pulley with a much smaller 2.75" unit. The new pulley will also have a different method of holding itself on to the Supercharger's shaft. We will use a steel pulley adapter that mounts like the original, with it's tight interference fit of a press-on pulley. Using the adapter will make future pulley changes much easier, as the new pulley will bolt to the steel adapter and not have to be pulled from the shaft with a special pulley puller like the stock Supercharger Pulley does. Our kit comes from RPM Outlet www.rpmoutlet.com and will match the new idler pulleys. MOTOBLUE™ True Grip Auxiliary Idler
The MOTOBLUE™ TRUE GRIP Auxiliary Idler Kit is designed to wrap the blower belt over 88% around the compressor pulley, effectively eliminating belt slip at any rpm. They use dual sealed bearings and require the stock factory belt guard to be removed. IDLER PULLEY'S
We will replace the stock Idler Pulley's with aftermarket Billet Aluminum Idler Pulley's from RPM OUTLET www.rpmoutlet.com . These new pulleys will be 90mm in diameter and will have double sealed bearings. We choose the silver one's for our Project. |
VALVE COVERS
To dress our 4.6L up a bit we bought a pair of Ford Racing Performance Parts Blue wrinkle finish DOHC Valve Covers. There's just not that many aftermarket pieces available for the Ford 4.6L, so you have to be constantly looking, unlike the Chevrolet 350, which seems to have an endless supply of dress-up and after market parts. I suppose that's one reason I went with the Ford engine in the first place, there's just not that many of them being used in the street-rod arena.
COIL COVERS
For a little more flash, we also purchased a set of Ford Racing Performance Parts, Polished Aluminum Coil Covers. They mount into a recessed area in the valve covers, and hide the coil pack that are used in the ignition system.
VALVE COVER BREATHER
Most Terminator engines have a problem of mixing some oil with the air that is going from the PVC valve to the intake track under high speed operation. While this is only oil vapors, the problem arises with the use of the supercharger and it's air to water inter-cooler located directly under the blower. The oil enters the intake track and collects in the fins of the inter-cooler. You can control this my placing the Breather directly into the track between the valve cover and the intake, as shown below.
POWER STEERING RESERVOIR
The stock Power Steering Reservoir is plastic and did not come with our engine, so we choose to use an aluminum Reservoir instead. We purchased ours from Speedway Motors, www.speedwaymotor.com . It will be placed somewhere in the engine compartment and supply the power steering pump with oil.
EXHAUST HEADERS
Project COBRA '33 will have a very heavy emphasis on performance, Hence we will be using performance Exhaust Headers. We purchased a set of BBK, www.bbkperformance.com full length Exhaust Headers. It is my intention to use these on Project COBRA'33, but there is a grave concern about weather they will fit between the frame rails since the engine compartment is so small. If the full length Exhaust Headers do not fit, then we will try a set of Shorty Headers.
SHORTY EXHAUST HEADERS
Header Bolts
We choose to go with Stage 8 
for the header bolts. They offer positive locking header bolts that do not and will not loosen. These special made header bolts are just the ticket for Project COBRA'33!
Stage 8's locking header bolts
OIL FILTERS
Our engine started out with the ideal of using only the Ford Racing Performance Parts Oil Filter. These are very robust filters capable of high RPM's without fear of rupture. They are also excellent oil cleaners that will last and keep our engine protected. Unfortunately, we had to abandon the stock Ford engine oil filter/cooler assembly that resides on the drivers side of the engine block. This assembly was to large, and interfered with the frame, not allowing us to get the engine down lower into the frame rail. We removed this unit and had to add a Moroso Oil Filter Adapter, Part # MOR-23681, which supplies a special bracket that allows you to tap into the two (2) oil passages (a inlet and outlet for the oil) and the coolant passage. We also had to now come up with a remote oil filter mount, so we also went to Moroso again and used there very nice remote oil filter mount part # MOR-23766. We chose to go with the 22mm oil filter bushings and will use the Ford Power stroke Turbo Diesel oil filters for our Project COBRA'33. These are very HD filters that offer high flow and are designed for great filtration, besides they are readily available and much cheaper then the previous filter choice.
Oil Filter Adapter & Filter Mount
Moroso # MOR-23681
Moroso Part # MOR-23681 Ford 4.6L Adapter Plate and Moroso Part # 23766 Remote Oil Filter Mount. Both parts are exceptional pieces, exhibiting quality machining and careful thought.
SUPERCHARGER PORTING
We are going to send our supercharger out for Porting. Earlier we purchased an additional supercharger and will use it for the one to be sent out. Porting allows the removal of material in certain areas that will result in better flow characteristics. Superchargers are very responsive to changes made in the case and both intake and port side of the superchargers. We will use the services of Steigmeier Engine Services, www.stiegemeier.com . They have a great program and reputation for Porting Superchargers, with advertised claims of 50+ additional HP through there Porting process, and they back it up with proven Dyno runs.
SUPERCHARGER POLISHING
Our stock Eaton Supercharger came from the Ford Factory painted Grey, while this is fine for a stock Ford Mustang, it is not appropriate for a Street Rodder. We will once again enlist the services of Steigmeier Engine Services to strip and Polish our Supercharger to a fine show winning shine.
Our stock brand new 4.6L DOHC Supercharged "Terminator" Engine.
