07 expedition gets 4bta'd

gwunter · Apr 28, 2016

The old girl is still up and running. Actually better than ever. After the hx30 install it just didnt seem to run right for some reason. And i finally figured it out. It seemed to have a miss feeling during higher rpm and heavy load. I checked everything i could easily check and was stumped on it ever since the hx30 install. I never hooked up my ksb cold start mechanism on the injection pump, which was in turn advancing my injection timing 5*!! I never hooked it up because it always started so well. But i still cant explain why i didnt notice this miss type feeling with the h1c. But now it runs really well and pull in the upper rpms better. When i was testing it after the ksb hookup, the boost went to 45psi!! I was shocked it did tgat. The waste gate was closed off. Ill need to get my waste gate controlled better as i beliece 45psi is way off its map....and i dont want it to eat a compressor or chuck a turbine. I have also swapped out the luk clutch for a spec stage 3.5 clutch.there is a night and day difference in these clutches. Im very impressed with the clutch. Nice smooth action and good engagement. Ive also purchased ford factory service manuals to straighten out some creature comfort issues. Compounds, innercooler, and better amsoil oil filter setup are still to come. Im also going to install a air fuel ratio gauge to better tune the IP, pyro is installed and running and she never breaks 1200*f yet. Its got some smoke down low i would like to get rid of.

gwunter · Jul 12, 2016

So I finally got this hammered out and about ready to drop in. A few hoses to make and some hose clamps to install and we will see if it fits in the engine bay. 1 pipe will be very very close. It was fun to make and would have been funner if I wasn't taking online calculus. I went with the hx35 over hx30w for this setup. Rumor has it it is a very street friendly setup. We shall see.

lincolnlocker · Jul 12, 2016

looking good!!

live life full throttle

god bless america and the farmer who feeds your fat ass

ja_cain · Jul 14, 2016

Looking awesome Shannon! Cain the wait to see how fast it builds boost and the smoke output.

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Notneb · Jul 18, 2016

Seriously awesome build, going to keep this in mind when I buy a Wrangler, since 4BT swaps are perfect for those.

gwunter · Oct 22, 2016

Something just broke between the rear drive shaft and flywheel. I'm thinking transmission input shaft. I'm kinda kicking myself right now.

gwunter · Oct 23, 2016

Found the weak link. It was the adapter shafts I cobbled together. Going to have to beef this up.

ja_cain · Oct 23, 2016

gwunter said:
Found the weak link. It was the adapter shafts I cobbled together. Going to have to beef this up.

Carnage. Any thoughts on how you are going to beef it up?

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gwunter · Oct 24, 2016

I got a plan just have to put it in motion. It's going to require the monarch and the kearney trecker!! I'm pumped.I got a 2"OD piece of steel here to use, but might look for something heavier.

ja_cain · Oct 27, 2016

gwunter said:
I got a plan just have to put it in motion. It's going to require the monarch and the kearney trecker!! I'm pumped.I got a 2"OD piece of steel here to use, but might look for something heavier.

I've got a little bit of stuff sitting around. When I get to the lab tomorrow I'll let you know what I have on hand. Just made a rolling pin out of 3.5" and have about 3" of that left. Also have some 2" to 2.5" mild steal round stock left over too. Probably about 1' to 2'.

Btw, I just have to quote the A-Team. "I love it when a plan comes together." Lol!!!!!

ja_cain · Oct 28, 2016

I found a 4" piece of 3 1/2" diameter stock and 2' to 3' piece of 2 1/2". Let me know if you could use any of it for the repair/modification.

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gwunter · Oct 29, 2016

Thanks, but I'm good to go. The shaft is all welded up. Will post pics later. It turned out well. The only thing that went wrong was one portion of the welding process kind of distorted the splines, so I'm in the process of dressing those up a bit.

ja_cain · Oct 29, 2016

gwunter said:
Thanks, but I'm good to go. The shaft is all welded up. Will post pics later. It turned out well. The only thing that went wrong was one portion of the welding process kind of distorted the splines, so I'm in the process of dressing those up a bit.

Cool. That's why I always weld then machine if I can. Can't wait to see the pics.

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gwunter · Nov 7, 2016

Well here's the pics of the new assembled shaft if anybody cares.

A lot of wire was used to fill those slots and the female splines got distorted from the high heat. Upon first time assembly it wouldn't mate up with the male part. I wound up having to grind a piece of high speed steel the approximate same shape as a tooth of the splines. I then had to use my lathe with a boring bar to straighten out the splines, like a broach. It took a while, but worked. I hate having to abuse my lathe like that but it's all back together now. Maybe someday I'll tool up and get the equipment to cut splines. I could cut external splines now, but internals are a whole new game.

ja_cain · Nov 8, 2016

Nice work man. I need to look into the different broaching methods for cutting splines. I hope it holds up for you this time.

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BrandonMag · May 5, 2017

Any updates on this bad ass build?

gwunter · May 6, 2017

No real updates other than the miles are stacking up. The wife drives it nearly every day and it's been very reliable. Still averaging 23mpg routinely. I was hoping for 25mpg but it just hasn't happened yet. The adapter shaft I built a while back is running just fine. Getting ready to install a turbo drive pressure gauge to see how hard the small turbo is being driven. I also have a air/fuel ratio gauge to install to better tune it's efficiency. But I still have a few small things to work out, like cruise, 4x4, AC. I'm also working on a device that will control/measure the travel of the advancement of the VE injection pump; so that I will know exactly what it is doing at all times. I also have all the stuff put together for installing a higher volume lift pump.

I see you have a bronco with 4bt in your sig. What's the skinny on it?