Gen 2 - Cobra Intake Swap

[Mad1stGen]

Not bad, not bad at all

You will need that heat wrap though especially for the folks who decide to keep their IMRC plates operational as the cables will pass exactly through that area.

I think Lonnie's solution from years back had similar shape to it.

 

[DLF]

Not bad, not bad at all

You will need that heat wrap though especially for the folks who decide to keep their IMRC plates operational as the cables will pass exactly through that area.

I think Lonnie's solution from years back had similar shape to it.

Thanks!

I thought about the IMRC cables, even though I'm not keeping them, and I believe that the cables are farther forward and lower than the tube, and shouldn't be an issue. I'll take a closer look at it though.

 

[DLF]

I made an aluminum washer to seal the two 45 degree flared EGR tubes at the connection behind the manifold.

20mm OD, 14mm ID, 45 degree bevel on both sides.

(Yes, the EGR tube is going to get blasted and coated :wink

 

[M Darrah]

You're right, and I'll probably recover the upper part of the stock tube with something like that. Unfortunately, I needed to remove the stock covering so that I could understand how to solve the problem.

Got any extra left?

I have six feet of it so I'll probably have some extra. Just send me a PM and let me know how much you need.

 

[marked8]

So, I believe that I've figured out a slick solution to the EGR tube issue.

Turns out that the upper end of the Gen 2 tube has some flexibility built into it.

So, after a little judicious bending, I was able to position it where I could create a short extension tube using the top and bottom ends of a '98 Cobra EGR tube. The extension tube I made will mate to the Gen 2 tube behind the intake. I'll have to put a copper or aluminum sealing washer between the tube ends, or perhaps I'll make a small double cone from aluminum on the lathe.

I need to finish welding my extension tube and find something nice to wrap it in, perhaps this DEI wrap from Summit. Or, maybe I'll send it to Jet-Hot and have it coated.

I'm not exactly sure why I went to all this trouble, but I did want to see if I could do it. :wink:

So here are the pics.

You are my new hero

 

[DLF]

I sent DEI an email and asked if their Cool-Tube Extreme would work in this application.

Bear in mind that top section of the the stock Mark VIII tube comes wrapped in a fiberglass sleeve similar to this, which is what I bought:

http://www.heatshieldproducts.com/productdetail/heat-shield-sleeves/hp-thermal-sleeving/55/47

It's good for 1000 degrees. The wrap you're talking about would serve the same purpose, but I would think that a loose fit would actually do a better job at protecting stuff around it because you've got a layer of air between the tube and the sleeve. I bought the 1 inch size.

And DEI responded:

Doug,

This product should work for your needs. It is best suited for reflective uses but should block some heat when used like you have described.

Dan Stark
Technical Support

So, I think what I'll do is buy some 1" DEI Cool Tube Extreme and put some 1" HP Thermal Sleeving under it. After I send my tube to Jet-Hot.

 

[M Darrah]

Doug, have you looked yet at the vacuum lines for the EGR and FPR, etc.? Just wondering how many mods will need to be made. I looked around and can't find anything to match those lines in the event that any splicing would need to be done.

 

[DLF]

Doug, have you looked yet at the vacuum lines for the EGR and FPR, etc.? Just wondering how many mods will need to be made. I looked around and can't find anything to match those lines in the event that any splicing would need to be done.

I have a couple of complete Cobra vacuum harnesses.

I'm going to use one of them on this swap. There will be pics later.

 

[DLF]

Here's a quick mock-up of my solution for the intake tube.

'03 Cobra upper tube and the lower end of the stock intake tube.

I've ordered a 1/2" to 3/4" reducing 45 degree silicone elbow to connect the '98 Cobra IAC tube to the '03 intake tube and I'll probably make a 3/8" to 3/4" Delrin adapter for the Crankcase vent hose on the other side.

I'm going to open up the injector wiring harness on this side to extend the TPS and IAC wiring.

 

[DLF]

EGR connector tube, welded, blasted, and now in a box on the way to Jet-Hot along with the crossover tubes.

 

[LINCOLNBOY]

Unfortunately for me, here they still do a visual to make sure you have not deleted something:



So if there is no solution to the EGR fitment problem my Cobra intake will be for sale and I will be looking for a supercharger instead. If DLF can't make it work, it isn't going to work.

Looks like you might look into doing the c-head swap instead.

 

[LINCOLNBOY]

Lonnie has done a cobra swap and install a egr. he did it on his 96 and don't know if he has done a gen 2. Here is his email. Not sure if it still active. lonnie@blueovalchips.com

 

[DLF]

Looks like you might look into doing the c-head swap instead.

Lonnie has done a cobra swap and install a egr. he did it on his 96 and don't know if he has done a gen 2. Here is his email. Not sure if it still active. lonnie@blueovalchips.com

Try reading the entire thread before posting.

All this is just clutter in my thread.

 

[LINCOLNBOY]

Maybe he has another way of doing it.

 

[DLF]

The '03 Cobra intake tube has a 3/8" fitting facing the rear. The rubber grommet in the passenger valve cover is 3/4". A 3/8" to 3/4" hose adapter is needed to plumb the PCV intake hose.

I suppose that you could buy one, but I decided to make one on the lathe from Delrin.

 

[beerdog]

Lookin good.

 

[driller]

... but I decided to make one on the lathe from Delrin.

Why does that not suprise me?

 

[KStromberg]

Your fabbing skills are priceless Doug. This is starting to look really good and you are definitely thinking this one through thoroughly. I am excited to see as you progress. I am slightly jealous how clean this is turning out.

 

[DLF]

Your fabbing skills are priceless Doug. This is starting to look really good and you are definitely thinking this one through thoroughly. I am excited to see as you progress. I am slightly jealous how clean this is turning out.

Thanks!

As they say, "The devil is in the details", and there are quite a few to work through. My intent is to not cut any corners and to make it look as stock as possible when I'm done.

p.s. I'm out of town for the weekend, so no updates until next week.

 

[DLF]

Today I drilled, tapped, and installed the vacuum fitting for the brake booster line. The flat metal plate is clamped in position to keep me from doing something stupid and drilling through the runner.