Honestly, I would just start with intercooler and tune. Possibly even going with E Blends. From there if you’re not satisfied, you can consider Turbos, Downpipes, HPFP.

 

Thanks for the feedback. And I had ordered the CVF Titan intercooler by the time you wrote, so I guess I'm off to a good start. I also had to make my first judgment call on related parts, and relative gains, when I decided against getting the hot and cold side piping kit. I figured I could add that later, and for the same price, I could get a CAI upgrade, which might be more beneficial. Still not sure which CAI to go with.

I have the dreaded exhaust manifold broken bolt and cold start ticking. I also have a whine/screech on hard acceleration, which I assumed was still the exhaust leak, but a knowledgeable mechanic friend believes is a turbo going. I know that this is a miserable job, and I plan to have the truck out of commission for a bit, so figured I'd upgrade the manifold and turbos, while I'm in there.

 

Trust me when I say this, a CAI won’t gain you anything but sound. Put that money towards something else. The stock intake is more than capable.

Warping manifolds are very common and almost every ecoboost owner has to go thru it. Luckily I have never warped a manifold on any of my trucks (knock on wood).

 

Makes me glad I have no manifolds on my 2.7, they are integrated into the head and cooled. But as long as diving into the 3.5's manifolds upgrading them and the turbos makes sense.
Improved CAC/intrecooler, tune, new plugs gaped correctly, all are quite reasonable. The intake is debatable, sound improvement is possible but at the sacrifice of poor under hood sealing and intake of the hotter air over a fully sealed airbox CAI as the OEM is. Improving under hood appearance is another benefit Power increase is only to be found with more radical modifications. There is something to say for a larger diameter cat back exhaust. Not in power gained but instead some added responsiveness, quicker turbine spooling reduced lag. At least I noticed this with a 4 inch catback exhaust, by how quickly it built intake pressure. KM

 

Thanks for the input on the CAI guys, and this is what I was looking for. I'll put it lower on my list of mods, and only if I can see where I would benefit from greater intake airflow, which might not be for some time.

I have made some minor updates, prior to this, including a larger Flowmaster cat-back dual exhaust (would have to confirm diameter). Added drilled/slotted rotors and larger pads, and the oil catch can. Added Fox2.0 suspension and larger rear block and air lift. Nothing too crazy, but figured I should try to improve stopping and handling capabilities before I just try to make it go faster.

On a side-note, I just get word that the CVF Titan intercooler that I ordered Sunday will arrive this week, so good to see that no supply chain issues there.

 

Doubt a catback will gain any power numbers.

 

An update on progress - I ordered the CRP exhaust manifold and stage 5 turbo upgrade yesterday. Also ordered the AMS turbo adapters. Then it was off to Ford, for $400 in associated nuts/bolts/studs/gaskets.

I'm having CRP put new internals in my existing turbos, so the truck will be out of commission for a bit, as I pull the turbos and ship them to Canada. I spoke with CRP first, and they have all of the parts in stock and the longest part of the job is supposed to be the shipping back and forth, so hoping this won't take too long.

Next purchases will be the colder spark plugs (SP542 Colder Performance Plug?); tuner (livewire TS+?); and some custom tunes (93 performance, not sure what else). Have not decided on 5-Star vs. MPT, or someone else. Wish I lived closer to one of the major tuners.

With the above setup, am I able to get the full benefit of upgrades without more updates to airflow or fuel pressure? Any feedback on the other planned items for the build (noted above) is appreciated as well.

 

If you are truly going the custom route, I would recommend @Boostking. He is probably the only tuner who truly puts time into their work. I’ve been with him for a few years now and I wish I did it sooner. There is SO much knowledge in that head of his. He will not push your truck unless you are comfortable.

Don’t be afraid to shoot him an email.

 

You may have a problem getting SP542 as those have been discontinued. Possible MC replacement for cold plug is the Ford Racing GT plug, or a more direct replacement from NGK 6510.
"Wish I lived closer to one of the major tuners." is the reason I chose BCB. Close enough for face to face interaction when I stop in at the shop. The others recommended are probably excellent also.
"With the above setup, am I able to get the full benefit of upgrades without more updates to airflow or fuel pressure?" The tuner you chose will be the person to ask this. KM

 

I had the @Boostking post on his OEM+ turbo project open in another tab, and I've been reading through it. The plan was to apply for a few college credits towards some engineering degree, if I make it through the whole thing, and retain even half of the information! Thanks for the recommendation, and I'll probably reach out.

Once I start working with a tuner, I'll ask about recommended plugs and some other items, and I've got a little time.

My CVF Titan intercooler and turbosmart vee port BOV just arrived, so only took 4 business days. The BOV was, admittedly, an unnecessary splurge, but man is it well made. I feel like just keeping it on my desk for a while, since nobody is going to see it, once installed.

Re: living close to one of the big tuners, I saw a video of someone bringing their truck to BCB and dropping it off for intercooler/exhaust manifold/turbos/dyno/tune, and was so jealous. I don't mind doing the work, especially if you have the time, but nice to have the option of a one-stop shop too.

 

@Gen1EcoMods did I miss it?
What downpipes are you going with?

 

I haven't decided on any downpipe upgrades yet. I'm still early in the build process, so I'll address any obvious choke points, as they show up in tuning. The only thing that I really needed to do at this time was replace the exhaust manifold and broken stud(s). When it looked like there might be an issue with one turbo as well, it was all the excuse I needed to just upgrade everything, while we are in there.

And, wanted to address heat before adding bigger turbos. So, I might not be going in the usual order for upgrades, but I didn't want to deal with another warped manifold either, and it's fun to do upgrades, so why not?

 

U must be a single man, no kids, no grandkids, no girlfriend. U aint gonna have Christmas money, youngun.
Sorry. You might be a wealthy bitcoin trader for all I know.

 

U must be a single man, no kids, no grandkids, no girlfriend. U aint gonna have Christmas money, youngun.
Sorry. You might be a wealthy bitcoin trader for all I know.

Hah, wife/kids/no crypto. After reading through all of the issues with the earlier exhaust manifolds, and seeing how Ford changed the later design, to address the issue, it just made sense to me to put in better parts. I'm not convinced that I have a turbo issue, but since I'll have them off anyway, and buying new hardware to reinstall, and CRP will just upgrade the internals in my turbos, and I have another vehicle to drive while this is being done, things just lined up.

The intercooler arrived yesterday afternoon, and I wrestled it in last night. Not a terrible job to do, but it would take half the time to do it again, and I likely never will, so passing along some notes. The new cooler is much thicker, and taking off the top of the shroud, around the powered louvers, was a pain. The top tabs finally released with a good pull, and no damage.

It's possible to install the new intercooler alone, and without a lift (I just had the truck on rhino ramps), but it's way easier to do if you completely remove all of the connecting hoses. Trying to line things up, holding the cooler with one hand, while the hoses are fighting you, was the worst part. Pretty smooth with hoses out.

 

Very nice. Do they make one that's not black. First vehicle I've owned that I actually like the chrome.
Also, just givin ya rib jabs I would do the same in person. Actually like these mod/build threads alot.

 

Re: the chrome. I actually went in the opposite direction, as the truck came with a chrome package, and I changed everything to either body color or black. Removed the stickers and excess badges, and painted fender badge and grill/tailgate emblems body color as well. For the intercooler, you don't actually see it, so no strong opinion, but the black finish was well done.

 

Yes they do. Not chrome but plain aluminum. KM

 

It’s said how much Ford cheaped out on 15+ intercoolers. They’re alright for stop and go traffic (stock form) but towing is almost impossible in 80+ weather. They even stopped painting them black. Atleast they made an effort on the Gen2 raptors and threw in intercooler fans.

 

Xmas came early this year! I finally had the time to take my truck off the road for a bit, so had the turbos pulled and sent to CR Performance. They sent the turbos back looking great, and packed very well. I also had the manifolds today, which appear to be really solidly built, and come with very detailed instructions on removing and replacing.

In general, CR Performance was a pleasure to work with, and I’m very happy with their customer service. A human actually answered the phone and could give intelligent responses to technical questions, without transferring to anyone. Now to get these in, and get back to tuning!

 

Also picked up the AMS turbo adapters, while we're in there.

 

Very nice upgrades, all I have done is upgrade the intercooler and replaced the plugs and new throttle body on our 2013, have an SCT programmer with some 5 star tunes to load when spring rolls around. But I did notice a difference in sustained power when towing since I installed the intercooler, IAT's under 5 degrees over ambient temps towing in 95 degree weather is very nice, I'll never need the pipe upgrade after seeing such a drastic drop with just the intercooler. Also have a 180 thermostat to install and will program the fans to come on at 200 instead of 225. No plans to upgrade the intake or exhaust since they flow more air than the stock turbos can produce, not to mention most aftermarket versions actually lose low end.

 

Yeah, I picked up the SCT Livewire TS+ and some custom tunes, but have not done too much with it yet. I tanked up with 93 octane and ran the 93 tune for a bit, and could tell the difference, but decided I wouldn't spend much time data logging or working with a tuner until I have the exhaust manifold leak fixed. And i have snow tires on right now as well, and it's probably good that I'll be forced to go easy on the new turbos until springtime. Things should be nicely broken in by the time summer tires come out.

 

You're fixing to have quite the grin on your face.
Be sure to share!

 

New CRP manifolds; Stage 5 turbos; and AMS adapters installed. Nothing leaking and all previous ticking on startup and squeal under load are gone. I'm doing my best to take it easy for a bit now, and let everything settle in before I add a tune and start dialing it in.

 

Very nice!
Is the drivability pretty good on oem tune?

 

Yes, no issues with 87 octane and OEM tune on stage 5 turbos, I'm just not getting the benefit of the upgrade yet, of course.

 

Been there!!! Good times await you my friend.

Did you decide on a custom tune?

I would strongly suggest Unleashed whose customer service and knowledge is on par to or with Boost King.

As for DP'S.... HIGHLY recommend getting some... One of the best "butt dyno" mods... Even without a tune. Remember air in air out.

The ONLY reason I bought a CAI is because my tuner recommended it due to all the other bolt ons.... It's like cancer man... I'm telling you.

I ended up doing AMS inlet piping as well to get better flow. On my 9th tune revision after my turbo swap and that is where "more air in" started to make better numbers...

Anyway, best of luck to you in that build. I sure enjoy turning wrenches on mine and it seems you do as well. Enjoy!

Sent from my SM-G998U1 using Tapatalk

 

Been there!!! Good times await you my friend.

Did you decide on a custom tune?

I would strongly suggest Unleashed whose customer service and knowledge is on par to or with Boost King.

As for DP'S.... HIGHLY recommend getting some... One of the best "butt dyno" mods... Even without a tune. Remember air in air out.

The ONLY reason I bought a CAI is because my tuner recommended it due to all the other bolt ons.... It's like cancer man... I'm telling you.

I ended up doing AMS inlet piping as well to get better flow. On my 9th tune revision after my turbo swap and that is where "more air in" started to make better numbers...

Anyway, best of luck to you in that build. I sure enjoy turning wrenches on mine and it seems you do as well. Enjoy!

Sent from my SM-G998U1 using Tapatalk

I ended up going with Boost King for the custom tunes, and we’ve been waiting until I can do some decent data logging. We were going to do a 93 octane tune, that is also good for towing. And then a 93 or higher octane tune, that is meant for pushing the performance a bit.

Yeah, I expect that I’ll have to add some new bolt-ons, to really give the turbos a workout, but I’ll follow the data and make small adjustments. The goal is to find the limit for performance, without upgrading engine internals, and still have a reliable daily driver. The one expensive upgrade that may be on the horizon is an upgraded HPFP, but at least it’s a fairly straight forward install.

 

If you have it near you, go with an E85 setup. I have FIC1000s and Raptor in tank pump and it has a decent amount left in the fuel system. Still drives like stock with proper tuning

 

Chad- just realized that I had been following along with your build, and when you got to the part where you went from a lift to a drop, with custom wheels, I was thinking "man, I just got the stance right, with the fox suspension, new rear block, airlift system, and powder coated a new set of raptor wheels." Every decision opens some doors and closers others, I guess, but I still want to tow with the truck, and take it out in the sticks sometimes, so my ultimate performance numbers will have to reflect that too. Still, the $1400 for a new HPFP would go a long way toward switching to E85.....