Procharger install pics.

Jeff,
The Ford part# for the steel tensioner is XR3Z-6B209-DB.
It's for the 96-99 Cobra. I bought it from Dan Newman in 2005
& it was $113 then. The annoying thing is that it comes with
a new belt, which you don't need for a blower install.
It also does not have the square hole for a breaker bar so I machined
a piece of channel iron (to fit over the arm) that has a square hole at
the end. This helps get out from behind the blower with the breaker
bar.

Mel C.
93 garnet/grey X2
Garage Queen w/ escort
 
Thanks for the number :)

Thanks for the number :)

Melmark93 said:
Jeff,
The Ford part# for the steel tensioner is XR3Z-6B209-DB.
It's for the 96-99 Cobra. I bought it from Dan Newman in 2005
& it was $113 then.

Melmark93 said:
Jeff,
The Ford part# for the steel tensioner is XR3Z-6B209-DB.
It's for the 96-99 Cobra. I bought it from Dan Newman in 2005
& it was $113 then. The annoying thing is that it comes with
a new belt, which you don't need for a blower install.
It also does not have the square hole for a breaker bar so I machined
a piece of channel iron (to fit over the arm) that has a square hole at
the end. This helps get out from behind the blower with the breaker
bar.

Thanks Mel!
I'll run the one i got till it gets old or slips then get the steel one. I'll file this away on the hardrive for future notes. If the normal one is aluminum and the good one steel both with steel pullies,i just cant see the aluminum one flexing sideways to pose a problem with the belt. Do they really flex that much?
This one looks pretty thick and stout with extra ribbing and raised channels on the outside compared to the original smooth side one, but i guess well see how she does.
More pics to come this weekend when i get busy this weekend again mounting the intercooler and piping. Cant really do much else with charger till i get the right bracket from THR. :fart :)
Click to expand...
Click to expand...
 
updates on install

updates on install

Going to work some more tonight on the intercooler install but heres a pic of the blower with the correct bracket and hardware i just got in mail from Fed Express. I sent the 2001 bracket,belt and hardware back to ProCharger and they sent this one right out. Thanks Shannon have a beer on me! http://]

http://
newpics07049.jpg
 
Last edited:
fitting good

fitting good

Looks like everything will fit nicely. I only have to mod two pipes. The intake side will be sliced where the black tape is, and the lower return pipe will have to be leangthened 4" to have the intercooler centered. It would of fit if i had mounted like the directions say against the radiator, but i wanted to make full use of our lower faring cutouts and have the cooler centered in there with a scoop on bottom. Ill not use the procharger 90 aluminum elbow off the throttle body, and keep my current C&L unit as it fits the engine compartment better with less mods.
Ill use those brakcets to mount it in front. More pics to come when i start playing with the fiberglass. :wink: http://]
 
When you dont have extra hands....

When you dont have extra hands....

Think like Jethro on Beverly hillbillies and use rope for temp holding. Heres some shots of the front valance foam insert that had to be cut to fit the depth of the intercooler. Also the passenger side of the front bumper will have its right inside corner cut to allow the 3" intake hose to come up though and not bulge out the front plastic on bumpercover. Finally, last shot is the angle i was going for. With a little fiberglass scoop at bottom on grille for the spoiler, and it should get plenty of ram air. http://]

http://
FrontfoambumperCutting004.jpg


http://
FrontfoambumperCutting006.jpg
 
Not to nit pick, but aren't you going to mount some electric fans behind your IC to help cool while you are in slower traffic etc. I didn't see any so I thought I'd ask.
 
Thanks John!

Thanks John!

driller said:
Looking good Jeff! :wave022:
Click to expand...

Its comming slow, but its on back burner now and i only get to work on it on weekends. Ill get out there tonight and do some more. After talking to Jeremi, i think im converting over to Blowthough type 05GT MAF that is the slot type. Ill have that welded into the current C&L setup im running. I sent him a barrage of questions (MAF inline of boost, or outside suckthough way yada yada) and he set me straight with good info. This will work out better for me also cause i dont have to reconfigure a bigger hole in passenger side for two 3"pipes. Also i can mount the MAF slot in a straight line with laminar airflow. I'll bet FORD wants a fortune for that bugger.:eek: I'll put my 90MM Lightning Big Air MAF on ebay, still works perfect when i took her apart for the blower install. haha Lonnie is gonna kill me when he sees all the things that need to be changed and retuned. :D
Well see when that time comes.
 
HAHA you no likey my rope trick?

HAHA you no likey my rope trick?

mlschultz said:
Jeff, It is really coming together now, and looking great :) LOL, I love the Jethro mod :cool:
Click to expand...

haha Yep Mike when i took that pic all i could think about was the beverly hillbillies with all that junk strapped to the back of the pickup...and Jethros rope belt. haha Yep its alot cleaner than duct tape and easily repositioned. That aluminum band on the left will have the same one mounted on the right side also when i mark the holes to drill with a sharpie.
 
Roadboss, I'd love to have the dual cooling fans mounted back there, but they aernt in the budget as of yet. Definate on the wish list for future though. I think with the scoop/spoiler im making it will get plenty of ramair going down the highway. Some guys dont even use an intercooler at all i see on some of the mustangs. That would defintely be cool having a suck one side, blow out front other side for idleing though traffic...
 
Special anti spark/dust shields... :)

Special anti spark/dust shields... :)

Roadboss said:
Just for future reference here's a link on the fan:

http://www.jcwhitney.com/autoparts/...10101/Ntk-AllTextSearchGroup?Ntt=electric+fan
Click to expand...

Thanks Roadboss for the link. Ill save it in the future mods file. :wink:

Made some more room with some coaxing from the Dewalt cutter and grinder. OHH THE HORROR! Chevy Heartbeat covers on a FORD motor! haha the Mustang guys would kill me. The rubber sides do make killer shields, sparks were flying everywhere in the garage. http://]

Now we go some room to work in here!...haha The compressor will live two inches lower than stock to make room for two pipes comming to the front.
You can see that lower right part of the bumper that had to leave to make room for the intercooler pipe comming back up and in. Also that oval airbox hole will be cleaned up tommorow with straight edges for a rubber seal to airbox up top for the conical filter.

LincolnCutting008.jpg
 
Here is the pic of what had to be cut out of the way. The yellow arrow is my incomming tube from the intercooler to intake. Its covered with tape to keep the dust and sparks out. The red circle is what needed to be cut out for the 90 degree bend of pipe going upwards.http://
LincolnCutting002.jpg
 
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