I finally got around to installing a Cobra BBK dual 65mm throttle body and '05 Mustang cold air intake onto my '97 F250 460 w/Speed Density. I may in the future convert this one to MAF or buy a California truck. But for now, I am trying to max out this SD 460.

I already had Hedman headers dumping into a single 4" aftermarket diesel exhaust. It may seem big, but it did not seem to hurt bottom end, as the truck is still quick out of the hole w/ 35's on it.

In custom fitting the TB and CAI to the truck, I'm not done yet, still fabbing up a heat shroud for the filter, and need another mandrel bent tube. You'll see in the pics, it's a bit redneckish, but it has worked extremely well, to the point that I'm a bit lean.

I will be trying an adjustable fuel pressure regulator and upping the pressure to hopefully get rid of the lean condition; any thoughts from anybody on going to bigger injectors instead/as well? My idle is still a bit high, 1000-1100 rpm.

I am trying to post pics, I may have to put them into a photo gallery or something, I'll let you know if I can get them up.

Even with the lean condition, I would guess that I've picked some serious power; from an off-idle start to 60 mph, I shaved off a full second, from 10.8 sec to 9.9, and that's with 35 BFG's. My work truck, an '08 GMC 2500 w/a 345hp 6.0, only does 11.9(although it does have gear in the box, but still weighs similar to my F250, 6400 lbs w/me in it). Another truck I tested, an '08 F150 5.4 3V, also only did 11.9 secs, an it had nothing it the box.

 

I was able to get the pics into a photo album; I cannot seem to carry them forward to here though.

Porting the inlet was straightforward, taking it out to 65mm was the limit; I had to remove a tiny bit of material from the inside to keep the flow smooth.

I port matched the idle bypass hole, between the throttle bodies, by drilling into the inlet deep enough to cut into the separator line of the inlet. This inlet does keep each throttle body separate, and even the lower inlet does as well, like a dual plane carbureted one.

The idle was too fast, about 1600 rpm with the idle bypass open, that I had to put the plug screw back in, and then drill it out 7/32 to try to match the idle holes in the butterflies that the stock TB had.

It still idles high, about 1000-1100 rpm, but I think it has more to do with it being a bit lean.

Notice the difference from the stock 51mm TB to the ported 65mm TB; I think once I get the lean issue sorted out, it's going to be very impressive. I would not hesitate to guess that I will have gained 100 hp with the headers, exhaust and the TB and cold air intake.

The '05 Mustang intake, with the extra 4" tubing, has to be less restrictive than the stock dual 2" tubing.

I will try to get some video of the truck racing some newer V8's, and possibly some Diesels, and put a link to them on Youtube.

 

Did you ever get pitures of this posted? I'm getting the same throttle body, I think. Haven't fully decided yet.

Did you get the idle figured out too?

 

I have a photo album done up, if you click on me can you then see my album, I'm not sure? Let me know if you can't, I'll try to post 'em on the thread.

The adj. fuel regulator helped, but it still idles a bit higher, right around 1000 rpm in park, but on the brake at a red light it drops to 800, so it's not too bad. I may experiment with the size of the bypass hole, currently 7/32, may have to go a little smaller yet.

The biggest obstacle has been the throttle cable, and getting the alignment right. The BBK unit pulls from a different angle, so I had to move the cable bracket up and back, and tilt it forward. It nearly rests against the firewall now, and it is a bit tight, the cables are bending more than what I would like. I just got a Transdapt spacer from Summit Racing, but it needs to be port matched as well, but it will give me 1 inch of space back to move the bracket off of the firewall. The tab that the cable attaches to on the TB is different, also. I am probably going to weld the little 'ball' on to the BBK unit, but I was told that a newer cable might work, like from a '99-up Lincoln Navigator, which has a similar factory TB.

It has been a bit of a pain, but well worth it. The truck pulls really hard right to the 4200 shift point, whereas before it would fall flat from 3500 to 4200 before shifting.

I think I'm still lean, though, and will be installing a wideband O2 sensor, I might need larger injectors.

I will finally be racing my buddy's '09 F250 V10, 362 hp, hopefully later today. I will be videoing it, and will post it on Youtube, and will attach a link to it here. I've seen dyno sheets on K&N website for both trucks, my '97 stock - 210 rwhp, an '06 V10 stock - 250 rwhp; I think I have at least 250 rwhp, so it should be interesting!

 

The wideband will help you alot with the air fuel ratio...Sounds like going to mass air or a custom tune will help you alot.... Lew

 

I put some more pics in the photo album with it nearly finished, just need to fab up a bracket for the coolant/windshield washer reservoir. It's still not pretty, but it def. blocks hot air from the compartment well.

My buddy with the V10 disappeared today, lol. I'll get him yet.