2002 Ford Mustang GT AFM Power Packages - NIkki's Six - Two-Valve Buildup Part 3
Kenne Bell Boost Pushes Nikki Wilson's Two-Valve Over 600 Horsepower At The Tire
From the April, 2011 issue of 5.0 Mustang & Super Fords
By KJ Jones
Photography by Courtesy of Anderson Ford Motorsport
You're probably thinking,...
You're probably thinking, "That intake manifold they're taking off still looks brand new." Yes, the Trick Flow 4.6 Track Heat intake had only a short stint on Nikki Wilson's Two-Valve stroker. It was just one of the performance upgrades that helped pump 363.51 naturally aspirated ponies to the feet of Nikki's '02 convertible. Of course, the Kenne Bell 2.6 supercharger includes its own lower manifold.
While our hobby seems to be consumed lately by new-product hotness for Coyote-powered Mustangs, we're keeping a close eye on what we hope will be a full-on resurgence of interest in New Edge Ponies and the Two-Valve, 4.6-liter engines that power them. Their engines can be set up to make big steam, their suspensions can be set up to ride like glass, and the overall cost to do everything falls far short of the coin you'll need to purchase and upgrade a newer car.
Hopefully all of you are current and up-to-speed on details of the really cool performance transformation that Nikki Wilson has been giving her '02 Mustang GT. For those of you who aren't familiar with the series, here's a brief synopsis of how things have gone thus far.
We received word about Nikki and her project idea-to upgrade her 'Stang's stock Two-Valve 4.6 and not break the bank-from our friend Rick Anderson of Anderson Ford Motorsport. As many of you know, we like to pursue cool projects that hit our radar, and we're definitely all about sharing information on self-doable upgrades that won't crush your wallet.
The gang's all here! Kenne...
The gang's all here! Kenne Bell's 2.6 super system includes everything required for a one-day, driveway-doable supercharger swap, including a billet-aluminum intercooler, low-loss/high-flow heat exchanger (and related hoses and hardware), a billet bypass valve, new gaskets, a 160-degree thermostat, and an Accufab Big Oval '03-'04 Cobra throttle body.
The subject of Nikki's concept, the 4.6-liter Two-Valve engine in her '02 rag-top GT, met every criteria for the kind of bullet we like to use for this type of exercise-it was running and, more importantly, it was bone-stock. After evaluating said stocker's oats on a Dynojet chassis dyno, initial highs were achieved through the addition of Anderson Ford Motorsport's all-motor-bolt-on packages-two affordable performance sets that ultimately brought the 'vert's power from 227.40 to 291 horses at the feet. However, like any other Ford-Blue-bleeding 'Stangbanger, Nikki's ultimate goal was to have a lot more power on tap.
So with big-steam in mind, the second effort in our three-part study was highlighted by Nikki and her crew swapping a D.S.S. SuperMOD stroker between the Pony's fenders, and hopping it up with Trick Flow heads and intake manifold, and a hot set of cams from AFM. Upgrade Number Two raised the power bar to the 363 mark and put the convertible 'Stang on a great path for even-more performance, which we're confident will come by way of the Kenne Bell 2.6-liter supercharger that we're covering in this final chapter.
The following photos and their captions present a few highlights of the blower install, which includes another cam swap, and the addition of a Kenne Bell Boost-a-Pump unit, to hopefully ensure the 4.6 has plenty of fuel to gulp down when the revs get high. The dyno results follow that pictorial, and officially close our chronicle of the rag-top's ascension from stone stocker to street rocker.
With the KB 2.6 blower being...
With the KB 2.6 blower being a "tuner" application, items such as fuel injectors ultimately are selected based on the anticipated or desired amount of horsepower (based on engine size, pulley combination/boost, and so on). For Nikki's setup, Ford Racing Performance Parts 60-lb/hr injectors were chosen. With additional fuel-system-support components being installed, these squirters will be more than sufficient for up to 700 rear-wheel horses.
While AFM's N-22 4.6 camshafts...
While AFM's N-22 4.6 camshafts are the hot ticket for naturally aspirated steam, its F-62 cams are the perfect profile for boosted Two-Valve applications. As such, a cam swap was performed before Nikki's new blower was set in place.
Fuel rails, injectors, thermostat...
Fuel rails, injectors, thermostat housing, and a few additional incidental pieces are fitted on the intake manifold before installing the Kenne Bell blower. As we mentioned in past articles, Nikki is a hands-on Mustang enthusiast, who bolted on many of the parts that were evaluated in our three-part study.
Because of some nuances in...
Because of some nuances in joining the KB intake and Trick Flow heads, a minor amount of grinding and light filing is required in four areas-on the intake manifold, inner gasket surface, heads and intercooler-due to a clearance conflict between the coil bosses and the valve-cover rails.
Achieving proper fitment is...
Achieving proper fitment is a finesse-intensive task that requires patience, and a lot of time spent grinding and fitting the blower assembly on the engine. It's also crucial to note that all intake ports should be covered with tape to prevent foreign materials from falling into the engine.
With everything properly filed...
With everything properly filed and clearanced, the Kenne Bell hardware is bolted down on Nikki's modular 5.0. A 3.25-inch blower pulley was selected for this effort, and should generate approximately 15 pounds of boost.
Adding the KB 2.6 on a Two-Valve...
Adding the KB 2.6 on a Two-Valve New Edge 'Stang requires swapping the factory throttle cable with one from an OEM '03-'04 Cobra. The necessary part is included with the supercharger system, and it's replacement is straightforward.
Nikki hangs the new heat exchanger...
Nikki hangs the new heat exchanger below her Pony's front bumper support.
Anderson's Power Pipe (PN...
Anderson's Power Pipe (PN AF-0117c), Abaco's DBX-97b digital mass-air meter (with air filter and Ford Lightning-60-lb/hr-injectors calibration) rounds out the air-inductive hard parts in an AFM/Kenne Bell 2.6 blower package for 4.6-liter Two-Valves. On the fuel side, although Nikki and her crew added the fuel pump from a Ford GT (see On the Dyno sidebar), a KB Boost-a-Pump also was added to the fuel system to help ensure fuel-volume is sufficient enough for making big steam.
The combination of an '03-'04...
The combination of an '03-'04 Cobra air inlet and top-mounted IAC valve present an overall height for the supercharger assembly that mandates performing delicate surgery on a New Edge's factory hood (if using an aftermarket bonnet is not your fancy).
A pneumatic cut-off wheel...
A pneumatic cut-off wheel or sheet-metal nibblers are the best tools to use for this segment of the project, as is a lot of patience. When complete, and with the faux hoodscoop's grille in place, the Kenne Bell's whine is the only indicator that there's a lot more going on under the hood than one would imagine.
All done, and ready to rock...
All done, and ready to rock the rollers of Anderson Ford Motorsport's Dynojet chassis dyno!
On The Dyno
Over the course of three issues, we've watched Nikki Wilson's New Edge convertible 'Stang be transformed. In her home driveway and garage, Nikki took the car from a feeble, stock 4.6 GT, to a snarling, 5.0-stroked, Kenne Bell-boosted Cobra killer.
With the blower installed, dyno tuning for this effort was left in the capable fingers of Anderson Ford's Danny Biggs, who manipulated a newly added Abaco DBX-97b mass air and the Pony's stock PCM (for fuel and timing calibration) using DiabloSport's Chipmaster Revolution tuning software.
Up front, a '99-'04's factory fuel pump will not support the type of horsepower this blower setup is capable of producing-with the 3.25-inch pulley installed, and certainly not with the bigger-boost 3.00-inch wheel. So, to help support the fuel demand for this effort, a Ford GT fuel pump was bolted in place.
|AFM 60||D.S.S||KB 3.25|
|KB 3.00||AFM 60 vs. KB 3.00|
The dyno graph depicts quite...
The dyno graph depicts quite the impressive progression of street-compliant horsepower and torque ... on 92-octane pump fuel.
As you see in the chart and graph, the Two-Valve 5.0 makes insane rear-wheel horsepower. With the 3.25-inch pulley, the KB churned 14 psi of boost with pump fuel only. As anticipated, the smaller pulley netted Nikki even more boost (17 psi), which resulted in 616 hp at the feet of her 'vert. However, it was noted that despite the combination of Ford GT fuel pump and a Boost-a-Pump unit, the setup requires more fuel.
While installing a set of twin SVT Cobra fuel pumps ultimately will be the route that Nikki must take for safe, consistent horsepower in the 600 range, we're beyond impressed with the performance that has been presented through simple bolt-ons, a stout engine upgrade and a supercharger, which are all DIY-able for mechanically inclined enthusiasts such as Nikki.