Howdy all, I had a few days to ponder and do research,..
My original goal was to have a little twin cam light weight road rocket. That goal is still primary. Its definitely achievable if I throw enough money at it. But as this project progresses, I want more and more to make this a project thats in the affordability range to the average guy.
There is no way around the initial cost of the engine, transmission, or bellhousing, those are all big money Items that you simply have to step up for. They're total cost is a significant part of the project. however there are three other major expenses,.. oil pan modifications, fuel delivery system, and ignition. those componets expense can easily dwarf the cost of the "running gear".
The Oil pan alone is quoted at 4+ hours weld time to make clearance and oil capacity mods, plus your own time making parts and getting it to the point its suitable for welding. It must be built on a jig, (or engine block) it must be stress relieved and then have the voids and crevices back filled with epoxy to promote smooth oil return. The Induction is a whole nother story, It can rapidly climb over $1,000.oo,.... in fact trying to stay under 1,000 using whats available is difficult, but not impossible.
There needed to be another way,.. I woke up one morning thinking about model cars, and it came to me. PLASTIC!!
(well kinda),...Polymers, (casting and laminating resins).
My valve cover is made of the stuff allready,.. and so is my intake.
I did some research and found resins that are stronger than aluminum that can withstand engine heats (for application) and chemicals, gas/oil/solvent.
And the cost for a gallon is less than one hour of welding. I am going to try and make a model of the oilpan I want,.. and make a mold. The beauty is I can design the sump anyway I choose to fit any application or volume of oil.
To solve the problem of expense in the induction department an intake manifold needs to be built that will accept a stock throttle body in the pinto chassis. This should be simplified a little since the stock manifold is a polymer, and can be cut down to yield a base plate that accepts stock sealing techniques, and a viable cross section to calculate runner taper. The result should be a very significant jump in hp with a very favorable side effect,.. the option to cut cost dramatically.
Using all oem parts would allow the use of the stock computer. At that point Painless Wiring could make you a harness for about $350 and flash your ECM for a performance update.No need for a stand alone system with a wide band o2 sensor. That route would still be available to anyone that wanted to wick even more hp, but the basic road rocket package could be achieved for several hundred dollars less, and give you easily obtainable inexpensive replacement parts.
I'm guessing,.. but from what I've read that makes power in these engines, an improved intake manifold with an ECM mod to a stock system should be good for nearly 200 hp.
I'm going to try the polymer route,.. If I can produce a high quality part that I can replicate, it makes this conversion a more realistic option for anyone that would want to try it.
Mick
