Coyote exhaust adapters arrived!!!!!

[oldguy668]

Well, thanks to Astglenn and his giant water pistol, these puppies arrived today on the Big Brown Truck.

http://i921.photobucket.com/albums/ad57/joe_leone/IMG_0561.jpg?t=1299731505

They drop right on to the studs on the Coyote block.

Glenn and Dave Borden worked out the details so the finished product looks like this

http://www.norcal-cobras.com/Mk4Build/content/bin/images/large/20110212IMG_0015.jpg

I was a little concerned with alignment, so I asked Glenn to go one step further and make this template for me

http://i921.photobucket.com/albums/ad57/joe_leone/IMG_0562.jpg?t=1299731505

Now, all I have to do is scribe the perimeter of the template and cut the excess from the stock flange

http://i921.photobucket.com/albums/ad57/joe_leone/IMG_0563.jpg?t=1299731505

So thanks to David and Glenn for working out the initial concept and extra thanks to Glenn for giving in to my whining and making the cutting template.

[astglenn]

Looks like they fit up pretty well. Do you feel the template will work like you needed?

[oldguy668]

Glenn, I have a fabricator who's done tons of trick stuff on my other builds who is going to do the fitup and welding. I'm sure this is going to be easy for him. Right now, the template is a tight fit in the new flanges, so maybe .050" clearance would be in order. The welding is going to require some beveling anyway.

PS: While we are on the topic, what about O2 bungs? I read 60 or 70 posts this morning about the preferred locations, and they were divided 50-50. Some recommended that the distance from the head was critical, so only one tube on each side gets sampled, and some said that sampling all the exhaust gas was more important, so the sensors went into the collector. WWWD (What Would Wayne Do)?

[Wayne Presley]

PS: While we are on the topic, what about O2 bungs? I read 60 or 70 posts this morning about the preferred locations, and they were divided 50-50. Some recommended that the distance from the head was critical, so only one tube on each side gets sampled, and some said that sampling all the exhaust gas was more important, so the sensors went into the collector. WWWD (What Would Wayne Do)?

I would put them in the collector so you get a sampling of all the cylinders. The only downside is the sensor may not stay hot enough at idle to be 100% accurate but at anything above idle they will read correctly. Don't mix up the O2 harness sides, bank 1 is passenger side.

[astglenn]

I agree with asking Wayne about this issue. That guy forgot more about fuel injection than we are ever going to learn. I have been doing a bit of study on the Coyote platform. Ford left some skin on the design bench over this engine. The engineers did a fabulous job on this platform and Ford spent some very serious R&D capital to make it happen. When the top tuners get familiar with this platform, I expect to see some truly remarkable, specific output numbers. This thing has it all. What a beautiful engine.

Are we thinking that .050" reduction to O.D. would be better? I will cut one at that dimension and send it to you to check it out.

[oldguy668]

Glenn: Not necessary to cut another one. The stuff is already at the fab shop. I'm just thinking of the next guy.

Wayne: Thanks for the quick info. I'm kind of lost without a distributor and a couple of carburetors. This must be that "New World Order" I keep hearing about.

[David]

Joe,

I would recommend a large chamfer near each of the top bolts(they will carrry the brunt of the load... and a slight chamfer around the perimeter and TIG welding it up. Id also recommend your fabricator clamp the adapter and existing header flange down to a solid piece of flat steel or welding table and tack weld around the flange and then weld it up... and not unclamp until it is cool.

My guess is all the welding should be done on the tube or back of the header. If he welds on the sealing side, the flange will need to be surfaced. Not a bad thing but it will add cost and time and they need to be very very careful to machine/surface it without introducing any angle to the flange.

Also, I would recommend a good .050 clearance. I designed a little template for a plasma cutter that worked much better than trying by hand. The 2nd one went much faster.

The template that Glenn did for you is nice, but not necesarry IMHO. Using the existing gaskets and the adapter works really well and allows one to make subtle adjustments by eye necesary since each header will be different from hooker.

Looking forward to seeing pics once your guy gets them finished.

David

[oldguy668]

My fabricator said he was going to use a heavy chunk of steel and bolt it through those two large holes in the FFR flange right through his welding table. He also talked about doing most of the welding on the side away from the head, so I think you guys are on the same page. I browbeat Glenn into doing the template because I consider myself the lowest common denominator for this type of work. The welder used it and said it made the job go smoothly. I'm picking up the finished product tomorrow. In the future, if Glenn simply adds the 4-1.75" tube holes when he makes a flange, the dropout piece would become the template.

[astglenn]

My fabricator said he was going to use a heavy chunk of steel and bolt it through those two large holes in the FFR flange right through his welding table. He also talked about doing most of the welding on the side away from the head, so I think you guys are on the same page. I browbeat Glenn into doing the template because I consider myself the lowest common denominator for this type of work. The welder used it and said it made the job go smoothly. I'm picking up the finished product tomorrow. In the future, if Glenn simply adds the 4-1.75" tube holes when he makes a flange, the dropout piece would become the template.

Hahahahaha! I have heard that before somewhere!

[oldguy668]

Glenn, "Analysis Paralysis" is my modus operandi

[oldguy668]

Steve did a super job on these. He tacked them from the back, and then bolted them down with the head side facing up. He then milled a shallow curved relief to accept the TIG filler. The result is a flat surface with none of the weld protruding. The gaskets line up perfectly, and the angle is right. He used Glenn's template to guide his plasma cutter, then finished off with a small grinder.

http://i921.photobucket.com/albums/ad57/joe_leone/IMG_0577.jpg?t=1300073715

[JGPierce]

Looks great. You guys are really coming along.

[astglenn]

Nice work. Borden did a good job designing these. I am really excited to see a set completed. If I may ask Joe, was the cost to get the work done, via a fabrication shop, really expensive? The cost of the work has been a big consideration in the design of the part. Please excuse the brash question, but if you could relate the amount of time that the fabricator had into the conversion, it would be really helpful.

G

[oldguy668]

Glenn, he had 2 hours into each side, and I paid him $200 for his 4 hours. Also, another important point is that he did not mess up the ceramic coating so repairs to that will not be necessary. I think the same adapters and template would work if someone wanted 4.6 shorty headers with catalytic converters or J-pipes.

[David]

Looks nice Joe... He must have wrapped something around the headers to prevent damage from the plasma. I tried something, it didnt work. I just assumed I would have mine recoated. He charged you a very fair $ for the work he did.

I nearly completed mine this weekend.

http://www.norcal-cobras.com/Mk4Build/content/bin/images/large/20110313IMG_0070.jpg

http://www.norcal-cobras.com/Mk4Build/content/bin/images/large/20110313IMG_0072.jpg

I still have more work to do on them but its a start.

Huge thanks to Glenn for hooking me up with this cool table!! It made welding them up worry free. There was only a few thou of warpage after unbolting from the table!

David

[David]

BTW, he did a nice job welding on the face...

I do caution people from doing that though as you really risk messing up the sealing surface I worked hard to preserve when designing the flanges. Any welding is going to eat into the ring that is left around the existing header flange.

Joe, I think it will be fine from the pics... but it would be really easy to mess up if you are not a super skilled welder. Of course anything can be fixed, it would just take surfacing the flange and adding cost.

David

[PhyrraM]

Both sets look great.

[oldguy668]

David, this guy is a virtuoso with a TIG. I got nervous when he explained how he planned to attack it, but the results speak for themselves.

[E-Ticket Ride]

That looks awesome! Thanks you guys for being the trail blazers. I thought the Coyote would be a fantastic choice when I first read about it, and it really looks like it still. My remodel is almost done, so I'm getting closer to an order for a roadster.
Can't wait!
Can't wait!
Can't wait!!!!