Boosted Falcon

Hi all,

Figured now that BrockyB8 has cracked the 12 second nut, there might be more interest in ITB's, so I thought I would say hi.

This is my EF project, it is a work in progress, it is also still my current daily (over 500kms a week) I have had it running with the ITB setup for about two weeks, so am still sorting it out.

First time on the dyno last week got 166rwkw @ 6,100rpm, had a great top end but idle and low down it was a bit jumpy, would idle at 1700 one minute then 2000 the next. made up some new linkages and found one of the throttle bodies had a bent butterfly, fixed that and it now runs like a dream, idles perfect, shit load more low/mid power, so am itching to get it back on the dyno and see what it can do now.

Specs:

King super lows
Boge turbo short throw shocks
Whiteline front/rear swaybars
235/40/18's
Standard bottom end (160,000kms)
Self ported head, shaved 40thou
Standard valves 39/47mm
Surecam custom grind cam
Double valve springs
AU MLS head gasket
6 x 48mm throttle bodies
24lb injectors
6 x BA/BF coil on plugs (currently removed due to burnt out igniter)
EMS 6860 ecu
T5 manual
Standard 3.08 diff (4WD System Lokka in the cupboard, waiting for 3.45 gers before putting it in)

Some pics

Been watching your build over at fordmods, great to see you here.
I love the attention to detail on the engine bay.

look forward to seeing what its capable of when its sorted!

What John said.

love the engine bay. very neat

Im pretty interested in those throttle body setups.. Can they go onto a stock engine?

Who did u buy it from?

very nice car mate, i love how simple your car is - no massive wheels/kit/bright colours.
and how your number plate says 666 then you got 166rwkw lol

burnt turtle wrote:and how your number plate says 666 then you got 166rwkw lol

Should have got 999

Seriously, love the set-up.

Ben

Looking good mate,The set up looks shit hot!

LOve it mate. Very nice engine bay. Good to see people putting time effort and money into a e-series.

I definitely agree.

Car looks the goods I reckon The pictures make it look like a scale model though!

Rollin wrote:Car looks the goods I reckon The pictures make it look like a scale model though!

haha, was thinking the exact samething, top car tho, throttle bodies are mint! they look similiar to BrockyB8's, who made yours?

He did! I'll let him post up all the build pics, but its pretty impressive stuff!

Cheers guys.

Some info about the setup:

It uses 6 x 48mm single throttle bodies from EFI Hardware


The manifold I designed and made, it tapers from 48mm at the throttle body flange down to 44mm at the head, I then opened up the intake port on the head to 44mm, and tapered it down to the throat, so it has a continuous taper from ram tube down to the port throat.



You can see the taper on the runners






This is looking through the manifold down into the port


For the head porting, the main area i worked on was the short turn radius, making it less of a sharp turn.




Throttle cable setup


Coil setup


With cover on to hide plugs and wiring


Future plans:
Oversize pro-flow stainless valves 41/48mm
get the head on a flowbench
Fresh bottom end, balanced and possibly some I-beam spool rods and flat tops to up the compression

Once I get another daily, full interior, engine bay repspray, hide all wiring etc.

Wish list:
Big brake kit
Coil overs all round
T56 <- may need a divorce first though

Holy shit, that's muchos impressivo mate! Love a tuff NA I6! If BMW can get over 300kW out of 3 litres, you should be able to get close with the good old 4 litre! Nice one!

would u make another throttle body setup?
looks very impressive mate.
cheers josh.

Impressive work mate. Engine bay looks great.

Thats awesome work! Ive been up most of the night researching this now haha dam u for making me spend money. So want one though!. I dunno how i missed the thread on ea/eb or whatever making 200kw :O .

Good to see someone with a little interest in making NA power

Wow intake is awesome, great car! Work quality is A1, love it.

Some great work there. Very impressive!

Mate i to noticed your thread on ford mods and it is a sensational job. I can see you take pride in your workmanship.
However what it's drive like compared to the bbm.
I know you mentioned great top end and jumpy down low but was that on the dyno only?
Just interested how your set up works when actually driving the car on the road?
Again its a credit to you

Very nice i have been watching your progress on psf.

korupd wrote:Mate i to noticed your thread on ford mods and it is a sensational job. I can see you take pride in your workmanship.
However what it's drive like compared to the bbm.
I know you mentioned great top end and jumpy down low but was that on the dyno only?
Just interested how your set up works when actually driving the car on the road?
Again its a credit to you

Thanks for the comments guys, it's been a fun project to get up and running.

Now that I have fixed the bent butterfly, it drives real well, even better now that I have sorted out the tune more, I spent a lot of time getting the TPS map running 12.5-12.8 AFR over the entire range, today I started leaning it out at idle and cruise by using the fuel override in the ecu based on map readings, that improved it almost to the point of being as easy to drive as it was before the cam, intake, head.

It has run flawlessly all week to and from work, and that is a mix of hills, main roads, and city traffic.

Being able to fine tune it with the EMS and Wideband in real time has been great, sitting at the lights I can try a little more/less fuel and then test the take off smoothness and AFR's once the light turns green. I am going to try and get it perfect, then hit the dyno again, the car feels like it has 50% more low/mid range grunt now that the few probs have been sorted, so am keen to see if it shows up on the dyno.

Thats sick!!!

Nice work mate, you have some talent!!

Love it, these are the sort of builds I generally have to travel to other breeds of car forums to see. Top shit to see it applied to an e-series and great effort it looks fantastic. How are you feeding the ITB's at the moment - do you have some sort of plenum/filter setup?

love the look of that setup.... the engine bay looks killer...

SNR wrote:Love it, these are the sort of builds I generally have to travel to other breeds of car forums to see. Top shit to see it applied to an e-series and great effort it looks fantastic. How are you feeding the ITB's at the moment - do you have some sort of plenum/filter setup?

At the moment it has some foam socks, but the plan is to build an airbox from alloy, and have the top in clear perspex so you can see the ram tubes, it will also allow for a cold air intake.


A couple of videos, first is one of the dyno runs, second one is how it now idles once the probs were sorted.

Great engineering. Do you plan on selling these as a kit?

Mate sounds like your on a winner here. I remember seeing my cousin's quad throttle GTiR and thought that would work good on a falc. Unlike you tho mate i had no idea how to go about. Good luck with the plenum cos we all know what you can do when you build that...... Did someone say boosted itb falc?

Such a good looking engine bay. I envy your vehicle building and photography skills!

Rollin wrote:Such a good looking engine bay. I envy your vehicle building and photography skills!

+ 1 here for both of them

Gawd damn!...I want!!!!

Meh, it's alright I suppose...

Kidding man, very neat setup. Looks like a sleeper too!

Well done.

if they made them intakes and of the shelf item id be in buying 1 in a blink of an eye Nice man !!!!

There is the possibility of these being kits in the not too distant future.

But for now I am still sorting mine out, I have designed up some different linkages to take care of heatsoak and expansion differences, it will pretty much allow each throttle body to be completely independent of each other (currently they are in three groups of two) will cut them out on the bandsaw tomorrow, and hopefully put them on over the weekend.

Heading back to the dyno Friday morning, and have a 300km country drive on Sunday, so will get to see what the cruise economy is like, might even do a cruise tune, that I can switch over too once on the road.

Nice set up mate. A mate of mine runs a similiar set up on his 4.1 xflow cortina it, like webers but with the fuel econ of fuel injection

Top job

I know a guy that runs a alloy head xflow triple weber manifold with a adaptor and triple webers on a 4litre speedway car the thing flys a little over 200rwhp on a next to stock engine with a good head and big cam

I like this stuff i run triple webers on a 250 xflow in one of my cortinas

Heres a shot of my engine