Looking to return to the land of the inline 6.. (LONG)

A

Anonymous

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Apologies for the length, but I figure most of this is useful if I'm to solicit proper feedback on this project.

I've had one I6 before.. a 200 in an '81 Capri. I was always rather fond of that car, but I had to get rid of it because the T-tops leaked badly and one door was screwed up pretty badly. Traded it in for a brand new '92 Dodge Daytona IROC w/ V6, then 2 years later traded that in for a '94 Escort LX Sport.. and I've been stuck in the land of 4-bangers ever since..

Until last month, that is.. when I traded that Escort for an '86 T-bird (the last year of the 4-headlight "aero-Bird") w/ the 232/3.8 V6+AOD and also got a carbed 351 Windsor in the deal. Obviously, the first plan was to swap in the 351W. (I had planned to convert it to SEFI) But now I'm getting the itch..

At first I gave serious consideration to trying to shoe-horn an EFI 300 I6 into this car. However, the more I poke into it, the more it sounds like it's too big to run without major mods to the car. So lately my research has been shifting toward the 250, IF I can find one around here. (SW Florida)

My ultimate goals with this car are to:
1) Make something that, barring major damage, should have no problem surviving for another 10 years.. I'm rather used to owning the same car for long periods of time now. I want something that runs like the proverbial sewing machine.. kinda how I remember my 200 I6 from 12+ years ago.
2) Make the "ultimate road-trip car", as I intend this car to replace my future wife's yearly (and possibly multiple trips every year) flights to Chicago and back. Even getting to another state from where I live requires around 300 miles' worth of driving.. so just up and visiting another state is far from trivial. (there may also be business reasons in the near future, which may require more trips similar to the Chicago run)

How do I plan to make the "ultimate road trip car"? Well, for one, I intend to line the entire interior with Dynamat and Dynaliner.. and put it on a diet in other places (hood, tubular A-arms, etc.) to make it quieter but pretty much the same weight if possible. For another, my plans revolve around a curious little unit from Gear Vendors that can add overdrive to most Ford transmissions.. and in the case of my (soon to be beefed-up) AOD, a double-overdrive. What it means for my car is that with my current tire diameter and rear-end gear, (3.27.. may also move to the 3.55-ish range if I get an 8.8" rear end) and the double overdrive (around .55:1 coming off the AOD+GV unit) activated, I'm looking at right around 1700-1800 RPM at 75 MPH.. (I rarely exceed 5 MPH over the rural Interstate speed limit here in FL.. I did all my speeding a decade ago) but with all the acceleration of the 3.27/3.5# gears intact otherwise. That's the part that brought me to choosing between the 351W I have (one in the hand, and all that..) and tracking down an I6.

(there are other plans, such as upgrading brakes and cooling capacity, but I cover much of the info less relevant to the engine swap over at CoolCats, a site devoted to mostly Fox-body T-bird/Cougars. I've cross-posted about this project between here, there, and Ford-Fox.org)

I don't seek a car that can do 0-60 in 4 seconds, although I do want acceleration between 45 and 75 to be as crisp as possible. I don't even care what quarter-mile time the car would be able to run. I have zero intention of racing anyone else with this car. What I seek is a respectable increase in power but with an emphasis on fuel economy. I'd even like it to be reasonably low on emissions, but I won't go overboard to get it there. We don't have emissions inspections down here right now.. but I'm not opposed to tossing in a high-flow aftermarket catalytic somewhere along the line. (I'm looking to stay single-exhaust, but will gladly move up to a large-diameter pipe.. was planning on a 3.5" single with the 351W, which is sufficient for applications up to 350 HP)

I also hope to keep some form of fuel injection. Right now I have CFI/TBI on my V6. I'd have gone SEFI with the 351W, (and still might have to, if I can't make this plan work) and would prefer a SEFI setup for this plan.. but could retain CFI/TBI, if needed.

OK, you made it this far.. apologies again for the length of this, and thanks for sticking with me. Must be a slow day at work if you've made it this far. :LOL:

What am I looking for here? Any feedback on making this work with the I6 as opposed to the Windsor. I've read up on the Aussie heads as much as I could find, except how to actually purchase an Aussie EFI setup. (I see the 2V on FordSixParts, and the coming soon stuff on Clifford.. but not much about EFI other than the aftermarket kits) I have a couple people I've talked to on ICQ for years that happen to live in Australia, but neither of them knows much about cars.. so I think asking them to ship me something like that might be awkward, if even possible (for them) at all.

A note about my level of experience: I've done car work before.. even worked in a junk yard for awhile.. but keep in mind that I've been away from modifying cars (except simple stuff) for over 12 years. The one and only complete engine swap I've done was 13+ years ago, a 4-banger from a Fairmont into a 4-banger '80 Capri. Needless to say I'm rusty. (bad pun?) I have friends who can help, including one friend who runs a repair shop about a mile and a half away from the house, so things aren't completely hopeless. I'm also doing hours and hours of reading every day on Fox-bodies, Ford EFI, and anything else relevant to either contingency of the project.. so I'm getting back up to speed as quickly as possible. But please forgive me if some (or all) of my questions are a little bit out there at first.

Well, thanks for reading this all the way through. At least I should have a very small chance of getting the same replies here that I have received when asking this same stuff on other relevant sites: "You should just use a 302". They have no idea how much that answer annoys me. :LOL:
 
Other relevant details:

- Either engine that gets swapped in will only be swapped in when I feel it's completely finished as far as major modifications. The V6 runs fine for now, even though the rear main oil seal leaks slightly.

- The car MUST have working (and in good condition) air conditioning, no matter what.. and I don't mean "2/60 A/C". :D I do live in southwest Florida, after all. We don't even get the benefits of the trade winds the east side of the state gets. Way too many oppressively hot days down here to NOT have A/C, especially on a car I'm building to be comfortable for the long haul.

- I will probably look into a high-output alternator, (I intend to build up the stereo to respectable non-ricer levels, and probably run a MSD 6AL box and better coil, as well as retain all my power options) but even so I realize I may need an overdrive pulley for it, if the car is going to be spending so much time under 1800 RPM.

- I wouldn't mind rigging up a mild supercharged setup, if possible.. but I have no desire whatsoever to mess with turbos. Fuel economy is said by many to increase somewhat with a supercharger, IF you're not running anywhere near WOT. Sounds good to me, if not insanely hard to rig up in this application.

- The car may see light towing duty, from time to time. I'm considering looking into a trailer hitch and a very small trailer.. something not much bigger than I'd need to, say, haul an engine around.. or a piece or two of furniture.

- The car's around 3200 lbs. as it is now, with the (supposedly around 350 lb) V6.. plus over 200 lbs. of driver. (supposedly a .35 drag coefficient, if you were even remotely curious)

OK, more later if it occurs to me.
 
8) you can convert the V6 to a sefi motor if you wish, just get the efi system off a later 3.8. for that car i personally would either stay with the V6 or go with the 351w. either six while they would fit the engine compartment, would i think be too tall for the slopping hood of that tbird.
 
Negatives first:-
If you are set on a 250 six, then you have to know that there are black marks against it :-

1.the sump,
2.correct older stlye A/c pump,
3.the mounts differ.
4.The issue of emissions. (Despite what you say, Americas emission policy is a ticking time bomb for factory unleaded cars. I'd say it would be a bad idea to jepordise the emissions aspect of any post 1980 car).
5. EFI is another stroke against it. (The log headed 250 is not impossible to eeee-ifie, but unless you have acess to a competant technician and machinist, I'd advise against it. Over here, we have an EEC4 TBI calibration which works Australian 88 to 91 Falcon ohc 3.2 and 3.9's, and is transferable. But it would never be legal to the letter)
6.Its even worse when you compare the heavy 250 to the super light weight 3.8. The 90 deg V6 is a honey of an engine. Its sooo light! The rear drive version are fully sorted, good quality pieces which are simple and have a growing aftermarket supply. They were a trendsetter which people quickly forgot after the oil glutt of 1982...when fuel prices stabilzed, Americans wanted Windsors again!!!! I'd personally not ever biff an engine like that out at all.

If you still want to persist, then I'd get a totally stock American 250 like Jacks old one in the tech section, and ONLY consider the following
Postives

1.The Fox Mustang swap was party documented by MustangSix back in Feb 2003, if you check the old posts. It was a tripple carbed Mustang or Capri III, and had
2. custom fabbed dual out headers were shown (not a great idea, but it solves the exhast flow problem),
3. special double hump sump made out of two 250 items and the engine was painted candy apple flip-flop with a gold anodized rocker cover.
4.It looks trick!
5.It will just about fit a T-bird, (but you'd be mad if you had to pannel hammer the hood to fit it over the leading edge of the tall rocker cover.
6.The 250 engine is a no brainer regarding swap to AOD or V8 transmissions.

The Fox body is like the last X body Granada's...it has no spring tower or cross braces, so a Offenhauser adaptor for three carbs would fit. There are issues over the progressive throttle linkage which means quite a lot of pressure is needed to actuate the outer barrels. The set-up would need a little work to accomodate the AOD kickdown/TV lever. Parts on parts, not good for reliabilty.

The last option? Go to Jacks next step, and Get a T5 equiped Australian X-Flow XF engine from Australia, either carb or EFI. Imitate greatness. All the bits are readily available in the states, and if you really must have an AOD, then there are adaptors to suit.

Wahtever you do, don't spoil a great Bird! It's a classic!

Hope you can hatch a plan which is reliable.
 
Heh.. not even getting very promising replies from an inline-6 site. A little surprising.

Some other notes:
- Swapping to any manual transmission is not an option here. The Escort I had for the last 10 years was a 5-speed stick. I got rid of it because my future wife cannot drive a stick, and neither of us are really in the mood to teach her how to drive one. (she'll eventually get her own LSC/T-bird/Cougar, but she needs to be able to drive this one for now) Not to mention I'm rather tired of manual transmissions. I don't even mind that this automatic is a column-shift.. it's something different for me. (every car I've owned since 1990 was floor shift)

- There's an inline-6 K-member for Fox bodies.. made for the 200s that went into Fairmonts and early Fox Mustang/Capris. I am attempting to find out if using one of these would solve the mounting question.

- The information could be wrong, but at least one site I've found recently claims that the small inline-6 should only be about 30 lbs. heavier than my V6. Compare that with a couple hundred pounds extra for the Windsor swap.. which will require extra suspension changes.

- I have no desire to convert the V6 to SEFI. I do, however, want whichever engine I put into the vehicle to be SEFI. If I were to do anything with a built-up V6 in this car, I'd probably look into the viability a Super Coupe engine swap. However, I'm not really fond of 90 deg. V6. Remember: Smoothness is part of the goal here. The Windsor will suffice, but in that department I'd rather have the 250.

- A built-up 200 might suffice, if the added deck height of the 250 is a problem.. (I may go with a cowl hood regardless of what changes are made to the car) but then comes the issue of mating it up to my AOD. (using an automatic w/ OD is also a requirement of the project)

- When I mentioned EFI, this is what I had in mind, not modifying a log: http://www.fordsix.com/crossflow.htm

I'm sure this doesn't answer everything.. but I'm rather preoccupied this afternoon.
 
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