HOW-TO: 3.5L EcoBoost Improve a bit on the X35 Phenolic Spacer

[Ecoboost_xsport]

Looks like a great product and look forward to getting it installed to see if it can mitigate IM heat soak issues further.  At the time of this write-up, he didn't have it listed on his website (X35Design) but emailing Steve over there will get you the info you need.

When I mocked it up and placed the hardware in the holes so I can see if I would need to do any port matching, I found it suffered from the same issue as the BBK throttle body.  Not the fault of the spacer, but more the fault of the IM.  The bolts holes are just too large for the hardware and allow for a lot of play.  This would make any attempt at port matching it futile as it would be difficult to place properly when installing it.  So...just as with the BBK, I used the same logic here. And it worked perfect...

https://youtu.be/8Nee7O5FjD8

Spacer with gaskets installed:

Thickness of spacer for those curious:

Dowels created for improvement:
5/16" OD,  0.035" wall thickness, 304 stainless tubing, cut to about 0.8" length (can't be any longer than 0.9")

Picked any 2 holes far apart from each other and drilled with 5/16" drill bit:

Drilled matching holes in spacer, same 5/16" drill bit:

Dowels installed into spacer:

Perfect tight fit onto IM:

Will need minimal port matching, mostly just a little of the spacer needs to be matched to the ports, but Steve did a great job of getting it super close.

There ya go.  I can probably drill the bolt hole very slightly using the same 5/16" drill bit for the match holes in the heads and push those dowels through the spacer slightly.  That would get this setup 100% dead-nuts tight and centered from head to spacer to IM...

Here is a video showing the port matching done on the IM side of the spacer:
https://youtu.be/q_kirU9loc8

On the head side, another 5/16 hole only slightly drilled to accept the alignment dowels:

Both holes drilled (hey, easy now...this is a family oriented forum!):

This is all you need it pushed through on the head side to get it to line up:

Rags stuffed into runners to minimize getting the dust into them while doing the port matching:

Used the dowels and the hardware to keep it secured down while porting:

Video on doing the porting on the head side of the spacer...

https://youtu.be/vFu4HktZLIc

All done and ready to mount:

 

[MKS Tom]

Excellent idea.

 

[Ecoboost_xsport]

I've been asked about making these available.

Anybody else interested? I could do these sets for, let's say $20 shipped. I'm not making much. About $8.50 is shipping ,PayPal takes 4%, plus cost of materials (per set). I'm making lil more than $5 a set for my labor.

LOL...damn, I might need to charge more haha.

 

[x35design]

Good idea - I had a similar idea in my mind at the start of the project too, but I wasn't sure if it would work for every car, given the giant holes Ford puts in the IM vs the diameter of the bolts...I figured I better copy their scheme, as there might have been a reason.  After seeing a few spacers get installed, it appears that they are all pretty similar and fit consistently though.

:beer2:

Oh BTW, I've about 14 left to make to finish the wait list, then the spacers will be set up in my store like a normal item, so if you didn't / couldn't get in now, they'll be available in the future.

 

[Ecoboost_xsport]

Good idea - I had a similar idea in my mind at the start of the project too, but I wasn't sure if it would work for every car, given the giant holes Ford puts in the IM vs the diameter of the bolts...I figured I better copy their scheme, as there might have been a reason.  After seeing a few spacers get installed, it appears that they are all pretty similar and fit consistently though.

:beer2:

Oh BTW, I've about 14 left to make to finish the wait list, then the spacers will be set up in my store like a normal item, so if you didn't / couldn't get in now, they'll be available in the future.

Thanks!

Sent from my SM-G965U1 using Tapatalk

 

[Ecoboost_xsport]

Finally have a few sets done if you are interested.

I know there were a few on other boards that showed interest, just hit me up here and I'll DM you paypal info if you are interested.  It'll be $20 shipped.  Thanks.

 

[Ecoboost_xsport]

Just got done port matching my spacer to my intake runners.  You can't even feel a change in the transition it's so smooth. This process is not possible without the alignment dowels.

Now, when I get my heads exposed, I'll entertain the idea of matching the bottom part of the spacer to the openings in the head...

"Those balls look smooth as eggs!!!" - Dave Chappelle

https://youtu.be/q_kirU9loc8

 

[Macgyver]

Nice !!!

Good thing its not a V12.......

 

[Ecoboost_xsport]

UPDATE Ladies and Germs!
Finally got this thing mounted onto the engine (video forthcoming on that), but here's a video on me doing the porting on the head side of the spacer...
https://youtu.be/vFu4HktZLIc