S197 Badger - 2011 S197 Gen3 Swap Build Thread Profile - S197 Mustangs

[Badger]

Capaldi send over the FP350S Setrab 960 and it is truly massive. Weighs in at ~10lbs as well.
I am afraid mounting this might have to wait till after the shakedown. Happy for any mounting suggestions or recommendations for anyone who might have brackets for this.

My old Mishimoto for comparison:

 

[Scootsmcgreggor]

God that thing is huge. Didn't know they made 960's anymore, I only found 948's.

I'm in the middle of mounting my 948 now. I have two threaded bosses on the front passenger side of my radiator that the Setrab bracket fit nicely on with only a bit of filing. Mounted sideways for straighter plumbing runs. Doing -12 for lowest pressure drop. The fittings and hose are huge but I think will be worth it. If you use the Setrab sandwich plate it has M22 ports so you can do full -12 fittings and lines without any -10.

Also the nomex honeycomb is amazingly tough and light. Even just for protecting the cooler and radiator for this fab phase its saved a bunch of dings.

Ducting is going to be a pain but worth it. Was good for 30* lower CHT on my Ecoboost.

 

[Badger]

God that thing is huge. Didn't know they made 960's anymore, I only found 948's.

I'm in the middle of mounting my 948 now. I have two threaded bosses on the front passenger side of my radiator that the Setrab bracket fit nicely on with only a bit of filing. Mounted sideways for straighter plumbing runs. Doing -12 for lowest pressure drop. The fittings and hose are huge but I think will be worth it. If you use the Setrab sandwich plate it has M22 ports so you can do full -12 fittings and lines without any -10.

Also the nomex honeycomb is amazingly tough and light. Even just for protecting the cooler and radiator for this fab phase its saved a bunch of dings.

Ducting is going to be a pain but worth it. Was good for 30* lower CHT on my Ecoboost.

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Awesome! Thanks for the pictures that is very helpful and gives me a good idea how to go about it. How many anchor points did you use for the cooler?
I got the Setrab plate as well to go -12 all around. Basically just like your setup but with 12 more rows. What thermostat are you going for?


Capaldi Racing has the 960 in stock. @ArizonaBOSS recommended going for this one while starting over.

 

[Scootsmcgreggor]

Nice!

The cooler has two bolts on the left side bracket and one up at the core support for the right side. Was going to do a 4th bottom right but it seems solid enough with the three.

I went with the 180* thermostat.

 

[ArizonaBOSS]

Please re-read the NASA rules regarding Fuel Cells (how the in-car tank will be treated). You're going to need a bulkhead. The lines themselves do not need to be contained within the bulkhead (if they are braided stainless or better), but consider your own safety in the case that a fitting becomes compromised somehow, you don't want pressurized fuel spraying onto you or up into the driver's area in-general.

It's cheap insurance. @captdistraction has a number of photos in his thread of the containment "bulkhead" that we fabricobbled together in his garage that will meet the intent and needs.

 

[Badger]

Please re-read the NASA rules regarding Fuel Cells (how the in-car tank will be treated). You're going to need a bulkhead. The lines themselves do not need to be contained within the bulkhead (if they are braided stainless or better), but consider your own safety in the case that a fitting becomes compromised somehow, you don't want pressurized fuel spraying onto you or up into the driver's area in-general.

It's cheap insurance. @captdistraction has a number of photos in his thread of the containment "bulkhead" that we fabricobbled together in his garage that will meet the intent and needs.

Already done and ordered! I did some more reading up yesterday after an initial quick glance at the NASA ST rules did now show anything. I finally found it in the CCR - Club Codes & Regulations

1. There should be a solid bulkhead completely separating the fuel tank, fuel pump, fuel cell, filler neck hoses, and vent lines, from the driver compartment.

Edit:
@captdistraction got any pics of your bulkhead? Can't locate any in your thread and I think last time I've seen your car it wasn´t installed yet.

 

[Dave_W]

Just for reference, the SCCA rule books also usually have a general chapter on "Safety" for things like this, so it can be written/printed once and cover all the individual class/category allowance chapters.

 

[captdistraction]

Already done and ordered! I did some more reading up yesterday after an initial quick glance at the NASA ST rules did now show anything. I finally found it in the CCR - Club Codes & Regulations



Edit:
@captdistraction got any pics of your bulkhead? Can't locate any in your thread and I think last time I've seen your car it wasn´t installed yet.

Microsoft OneDrive

1drv.ms

 

[Badger]

Microsoft OneDrive

1drv.ms

Dude, this is awesome. And accessible when the trunk is open.
Here is what Chris did. Just pulled it from the folder he posted:

 

[Badger]

Decided on a mounting spot for the surge tank: Back in the trunk.
The screws for the tail lights neatly take care of the relay and the fuse as well. Now I got to order all the missing fittings and route the rest.

AME 50-1200 E85 installed:


Setting up the intake manifold with the Radium rails and return style fuel system:



2011 TB be gone, 2018 TB here we go:

 

[Badger]

The FP350S pan has finally arrived!
Weighs in at a hefty 16lbs.





Gasket aligns good enough for the bolts to drop through without issues:

 

[Badger]

Time for a sanity check: Do these welds look fine or will I have to get anything adjusted?

I will be dropping off some things at the welder next week (oil pickup support etc.) so now is a great time to gather some feedback.
@Fabman @captdistraction @honeybadger

 

[Fabman]

Time for a sanity check: Do these welds look fine or will I have to get anything adjusted?

I will be dropping off some things at the welder next week (oil pickup support etc.) so now is a great time to gather some feedback.
@Fabman @captdistraction @honeybadger

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I see nothing bothersome here.

 

[Sjohnson1800]

There’s a little arc burn on the one door hinge but nothing bad at all looks good to me

 

[Fabman]

There’s a little arc burn on the one door hinge but nothing bad at all looks good to me

Yeah there’s a little carbide precipitation but being what this is its probably inconsequential.

 

[Fabman]

Might wanna knock that little knob off there so it doesn’t end up In the motor.

 

[Fabman]

Nice work!

 

[Badger]

Nice work!

View attachment 71849

Not mine sadly. That is what Chris did on his.

 

[Badger]

Awesome, thx guys. Much appreciated! Sounds like good news to me and I will take care of that knob.

I test fitted the pan and it fit without major issues. I will have to get some clay and test the pick-up tube clearance next.


That said, the FP350S gasket does not fit a Gen3 without modifications. The FP350S gasket is actually the same part number as the gasket in the GT500 oil pan kit, go figure.


I ended using the gasket that I initially trimmed for the gen3 pickup for GT500 pan and it all came together without issues.

 

[Fabman]

Not mine sadly. That is what Chris did on his.

Yes I know, I’m on my iPad and it’s not post friendly as a desktop.