Gbranham's MkIV 427/IRS/TKX Build Thread...Spark Plug Shenanigans

I received all my Breeze bits this week, and got my coolant system plumbed. I bought 3 gallons of premixed coolant, and threw it in the system, but I need more apparently, as the level hasn't reached the top of the manifold, where I removed the plug just in front of the water temp sensor. Thinking another gallon or so will probably do it. The lower radiator hose is a bit close to my serpentine belt, but I have a inch or so clearance, so that should be plenty. I routed the Breeze lower radiator hose kit above my power steering cooler, and just below the center of the front 2" X-brace; if that cooler wasn't there, the lower stainless tube could sit lower, and likely give me more clearance at the belt, but there's no room to lower the cooler. Should be okay. My Remflex header gaskets and ARP header studs should be here today, so I might bolt all those bits up this afternoon or tomorrow. My plug wires will be here Thursday, 3/13, so I might be attempting a first start next weekend. Already getting nervous/anxious, just thinking about it. I've built several engines over the years, and never had a failed first start (knock wood), but it always makes me so nervous, thinking about all fasteners that have to be right for it to a)not leak like a sieve, and b)not fail catastrophically. Hah! Oh well, part of the experience!

Have a great weekend, everyone!

Greg

Attachment 211260Attachment 211261Attachment 211262Attachment 211263

Can't wait to hear that baby rumble!

I received my Remflex header gaskets and ARP header bolts this afternoon, along with some Permatex anti-seize for the header bolts. Those Remflex gaskets are thick!!! I had some fun getting the ARP washers and nuts threaded on the studs. I had to flat-spot several washers because the header tube was so close to the bolt hole. Also had to 'thin up' a 12-point wrench to get all the nuts tightened up; I took the wrench to my bench grinder, and removed a lot of material around the closed-end head of the wrench. That gave me the clearance I needed to snug up the header stud nuts. The entire time I was doing this, I kept thinking abut the Coyote folks...I was thankful for the space I had to work, even though it was cramped...can't imagine the frustration bolting up headers on the Coyote in a MKIV. Once all that was buttoned up, I thought I'd throw on my FFR-supplied side pipes, but nope...I can't find the sidepipe to header bolts, washers and nuts. I think they are a hex head M10 x 1.50" long fastener (maybe), and if that's the case, I can't find them. Oh well...Amazon is my friend.

Anyway...it was a productive evening in the shop, with great weather. Highs in the 70s this week...WooHoo!!!!

Greg

Attachment 211282Attachment 211283Attachment 211284

Yeah, now that I’ve done it Coyote headers are an experience for sure.

FYI this thicker gaskets will compress with heat cycles. After you get say 20 hours on the car do yourself a favor and re check your torque. She is really looking sharp.

What do you think if the build compared to the MKIII?

Quote:

---

Originally Posted by gbranham

Attachment 211282Attachment 211283Attachment 211284

---

Are those headers polished stainless? They are sure gorgeous. I had polished stainless and it didn't take long for them to turn ugly so I had them ceramic coated. Very glad I did.

My new cylinder heads have both sets of header bolts, standard and spread. I wish I had spread bolt headers for the reasons you mentioned. I might change them out one day with some Gas-N ones, I like his ball joint better than the Factory Five ones. I've talked to Georgie about a set, I'm just not real big on paying in full and waiting 5-6 months for my parts.

Looking good Greg! Crank it up!

Quote:

---

Originally Posted by Mike.Bray

Are those headers polished stainless? They are sure gorgeous. I had polished stainless and it didn't take long for them to turn ugly so I had them ceramic coated. Very glad I did.

My new cylinder heads have both sets of header bolts, standard and spread. I wish I had spread bolt headers for the reasons you mentioned. I might change them out one day with some Gas-N ones, I like his ball joint better than the Factory Five ones. I've talked to Georgie about a set, I'm just not real big on paying in full and waiting 5-6 months for my parts.

Looking good Greg! Crank it up!

---

Those are the kit-supplied FFR headers. They are pretty, but I suspect that won't last long.

Greg

Quote:

---

Originally Posted by Blitzboy54

Yeah, now that I’ve done it Coyote headers are an experience for sure.

FYI this thicker gaskets will compress with heat cycles. After you get say 20 hours on the car do yourself a favor and re check your torque. She is really looking sharp.

What do you think if the build compared to the MKIII?

---

I can't say the MkIV build was much different than the MkIII, but it's been 20 years since I built my MkIII, and I think I'm a better wrench now, so it went together easier.

Looks like your getting really close to first start !
I can't wait to hear it !

Hey Greg,

Looking good! :cool:

I noticed your Breeze radiator fan shroud appears to be coated or painted. I like it and am considering doing the same for my build. It's about the only piece that I'd like to coat on the radiator. I noticed some previous Builders added cosmetic (and practical) touches to the front side of the radiator. Are you considering doing that, too?

Craig C

Quote:

---

Originally Posted by cc2Arider

Hey Greg,

Looking good! :cool:

I noticed your Breeze radiator fan shroud appears to be coated or painted. I like it and am considering doing the same for my build. It's about the only piece that I'd like to coat on the radiator. I noticed some previous Builders added cosmetic (and practical) touches to the front side of the radiator. Are you considering doing that, too?

Craig C

---

I powdercoated my Breeze radiator shroud the same as all my aluminum bits, and I have (albeit uncoated) Everson's nose aluminum, too. I like his solution vs the FFR nose aluminum pieces. I'll probably polish Everson's piece, but I won't powdercoat it.

I got another gallon of coolant this afternoon, and needed about half of it to get the cooling system full. I 'milked' the upper and lower radiator hoses quite a bit, and burped out several air pockets. Also filled the reservoir about 1/4 full. Should be good to go until I get a few heat cycles and the rest of air burped out. Next up; spark plug wires, bolt up the side pipes, but an air filter (likely the K&N lowered-base model), and install the ProFlo4 Air Temp sensor in the air filter. Getting very close!

Have a great week, everyone! 70s in KC all week. WOOHOO!!!!

Greg

I found this in the shop today, and thought it was kind of cool. Some of you remember my MkIII...Ford E4 red, no stripes. Well, here's some leftover paint from that car. I was surprised the paint wasn't dried up, after sitting for so long.

Attachment 211307Attachment 211308Attachment 211309

And a few reference pics...

Attachment 211310Attachment 211311Attachment 211312Attachment 211313Attachment 211314Attachment 211315Attachment 211316Attachment 211317

Looking great!!!

Well, today was the day! Got my plug wires installed, my sidepipes put on, and filled it up with 5 gallons of 91. Started up the ProFlo4 app on my cell phone, and did the things. Super easy. First turn of the key, and no fire. Cycled the key to get a bit more gas in it, and it fired right up! No drama, no sputtering, no backfiring...just settled into an easy 725 RPM. I adjusted the idle down a bit, and let the engine come up to temp. Got a bit warm, but I suspect it's got some air in it still. It puked coolant into the reservoir, so I'm going to let it cool down and draw some back in, and do that several times to get the air out. Fan came on as it should, and really wasn't that loud. I need to set the IAC on the ProFlo4, as it was sitting at 40%, and you could hear the intake sucking air. Only one simple leak at a clamp around the coolant t-filler. All my gauges worked perfectly, too. Sweetness.

https://youtube.com/shorts/tx9tJAyvd...GAKdQfj12cb_w5


Pretty good feeling! Woo-hoo!!!! Have a great weekend, everyone!!!

Greg

WooHoo! Way to go!

Remember, no video it didn't happen:)

Quote:

---

Originally Posted by Mike.Bray

WooHoo! Way to go!

Remember, no video it didn't happen:)

---

Yes sir! Just added the Youtube link in my last post.

Greg

Got my IAC adjusted, and took a very gingerly ride down to the end of my street and back. Brakes are awesome, but the power steering...it's a thing of beauty. Take it from a guy who has owned an FFR with PS, and one without. If you're on the fence, just get power steering. So, so, much better.

That sounds awesome! Congrats Greg!!

Attaboy Greg! I like hearing that the Pro-Flo fired right up since that's what's going on the Mk5 :)

Congrats!

Jeff

The loop is called a shock coil. The pressure inside the line is equal in all points in the system so the line wants to be straight. The coil allows it to expand slightly when pressure is applied and alleviate the hydraulic shock.

Quote:

---

Originally Posted by Jeff Kleiner

Attaboy Greg! I like hearing that the Pro-Flo fired right up since that's what's going on the Mk5 :)

Congrats!

Jeff

---

It's so cool. I'm watching it idle from my phone right now...

Attachment 211467

While idling in the driveway tonight. They sure get hot! AFR of 12.6...just about right.

Attachment 211486Attachment 211487

Wow… that’s wild…

No way you should be seeing that at idle Greg! This, plus the way the engine sounded in your first start video makes me think that the timing is retarded. Pro-Flow controls timing but you have to do an initial physical setting to synch it with the ECU then changes can be made thru the tablet. Have you been through that initial setup.

Jeff

Quote:

---

Originally Posted by Jeff Kleiner

No way you should be seeing that at idle Greg! This, plus the way the engine sounded in your first start video makes me think that the timing is retarded. Pro-Flow controls timing but you have to do an initial physical setting to synch it with the ECU then changes can be made thru the tablet. Have you been through that initial setup.

Jeff

---

I did, yep. I set the initial timing to what I believe to be 12 degrees BTDC, then let the ProFlo do it's thing thru the setup Wizard. I can tinker with it today. When I set it to 12BTDC, I removed the #1 plug, and turned the engine by hand until I felt compression with my finger over the plug hole. I then put a screwdriver in the plug hole to feel the piston come up to TDC. I then looked at the balancer, and it was indeed on 0. I then rotated the engine counterclockwise to get the timing pointer at 12BTDC, then reset the dizzy to have the rotor pointing directly at #1. When I fired up the ProFlo wizard, there's a step where you have to 'unlock timing' in the wizard, verify 12BTDC with a timing light, then 'lock timing' in the app. While my timing light was having issues, I couldn't positively verify I was at 12BTDC, but I feel pretty confident in it. Nonetheless, I'll give it a go again today.

Hey man, big step!! Keep it rolling.
Higgy

Quote:

---

Originally Posted by gbranham

https://youtube.com/shorts/tx9tJAyvd...GAKdQfj12cb_w5

---

Okay I believe it happened now lol

That's sweet! Nothing compares to the rumble of a 427 SBF.

I agree with Jeff, that looks like the timing is retarded. Time to verify with a timing light.

I'm not familiar with the Pro Flo software but most EFI systems that control timing have a function where you can lock the timing at a value you select. On mine I locked it at 20 degrees and used my light to set it. Actualy my wife used the light, she has better eyes than me:)

https://youtube.com/shorts/Z6fe29wFXuM

Congratulations Greg one of the better milestones of a build.

I’m assuming you already know this and just did it for go carting but are your side pipes are on the wrong side? If that was on purpose pretty good idea honestly.

Quote:

---

Originally Posted by Blitzboy54

Congratulations Greg one of the better milestones of a build.

I’m assuming you already know this and just did it for go carting but are your side pipes are on the wrong side? If that was on purpose pretty good idea honestly.

---

Yep...I put them on that way so I had a way to suspended them.

Greg

I reset my base timing again. Took out all the plugs so I could turn the engine by hand easier, and brought #1 up to TDC on the compression stroke. Marked the harmonic balancer at 12BTDC, fired it up and dialed in 12 degrees with my timing light. Cycled the ProFlo and ran thru the Set Base Timing wizard again, and all seems to be operating well. I pulled it into my shop and turned off the lights and didn't see the headers glowing. When I temoved my spark plug wires to remove the plugs, several of them came off pretty easily. I don't think I put enough oomf on all of them to get them to snap tight. I did this time. Here's another video. The exhaust smells a little different now...maybe not as rich smelling.

Greg

https://youtu.be/YF9snZL01ZE?si=wIFAaVG5yI1SOWM0

Time to cruise around the block!

Definitely sounds better now. In your earlier video it was sounding like an old Ford tractor which immediately made me think that the timing was retarded. Retarded timing will make the exhaust glow because combustion is still occurring as the exhaust valve opens.

Jeff

Thanks, gents! I think we're on the happy path now. Time for some light go-karting. Fortunately, my neighborhood is all cul-de-sacs...one way in and one way out, so we have very little traffic. Perfect place to log a few miles.

That's awesome Greg! Your progress and videos got me motivated to pick up my pace a little bit :)

Craig C

Quote:

---

Originally Posted by cc2Arider

That's awesome Greg! Your progress and videos got me motivated to pick up my pace a little bit :)

Craig C

---

Yes! Spring is coming. Chop chop!

I'd say we got it sorted. This is after 15 minutes of idle. Attachment 211529Attachment 211530

Time for ceramic coating. My headers looked like that after a bit of running, I'm very happy I had them coated.

Quote:

---

Originally Posted by Mike.Bray

Time for ceramic coating. My headers looked like that after a bit of running, I'm very happy I had them coated.

---

Yep, that's on the list.