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How much can the Block Handle

27K views 101 replies 13 participants last post by  JimmyD750  
#1 ·
I've started to slip into this hole of building out everything, rods, pistons, transmission, single turbo, E85, new diff, and now I am worried about the block. How much can the 3.5L block take. (P.S. this is not an F-150 build, it's a Transit Van build...)
 
#3 ·
It is the EcoBoost. I am looking to convert to a single turbo with some custom forward-facing turbo manifolds and the XTR-94 single turbo kit from Precision with 1.0 A/R.

But really the strength of the block dictates how much power I can put into it.
 
#10 ·
The 3.5 Ecoboost is an open deck design. That, if anything would be the limiting factor in how much gaff the block can take in my view. I've seen pictures of modified blocks, where the shop went to the trouble to convert the block to a closed deck in order to stretch the envelope.
 
#12 ·
900-1000 hp from a single turbo Transit Van build? I can't wait to see this build thread! Definitely a first.
 
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#15 ·
Than you! I am still in school but have been saving for a project like this for a couple of years, won't have much progress until about December when I pull the engine over break! I'll probably create an actual thread titled "Drag Van" and I can tag you in it!!
 
#17 ·
I feel like not to many people would build a drag van. I’m old and the term was sleeper, If it was stock looking but fast. Your sleeper van would definitely tweak some minds when you blow them away. Nobody wants to lose to a van. But seriously, you will spend crazy money to get to your horsepower. Good luck on your project and hope to see it in action some day.
 
#22 ·
I feel like I've been the Debbie Downer in your threads. I really don't mean any offense with my posts. I'm an old HP freak and have built and maintained some rather high HP engines. I'm also very much a realist. If you can't afford something similar to the Stage 3 bottom end build mentioned above I think you'll have a very difficult time making a 3.5 EcoBoost live at 900 - 1000 HP.

It's one thing to hit those numbers. It's an entirely different story driving it 2 consecutive weekends in a row. Even after you get the bottom end to a place that will support that kind of HP you're still talking some very specific, basically one-off parts that cannot be cheap. There are guys that will build those type parts but it's gonna cost you.

May I ask what kind of budget you are planning on for an engine build to fit this build? I'm very much looking forward to seeing this build come to fruition.
 
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#23 ·
Well funny enough, I just got off work and got a promotion! One of our GMs left and I am fairly confident that I will be able to afford it! The budget I am looking at is at most 27k, but I will go to 30k if I have to. I have been looking at Full-Race's raptor turbo manifolds and the XT2-61T4 Twin Turbo Package from Precision. Along with E85, a built 6R80 trans with the 4R200 planetary gear, I think I could make this possible. I am 17, going through high school, working two jobs, I've been going to car shows almost my entire life and I have really wanted to make something unique. And after I picked up the van I knew it was it.


All in all. I will go with the 4.2L, I really think to get anywhere near my goal of a 900-1000Hp street/drag Van, it's my only option.

The only thing I truly need help with is an Intake Manifold and the fuel systems. J2 Fabrication use to make one which was billet, link below:


But the problem is, it's for a Gen 1 Engine. I am fairly certain I would be using the same heads since there really isn't much I have found to improve other than say like bearings for the Cams.

The other thing is, Gen 2 is Port and Direct Injection right? Is there any way to make it one or the other? Buying 12, 1700cc (because the pump is mechancical) E85 compatible fuel injectors is absolutely bonkers...

If anyone has any tips to make the project a little cheaper, and maybe make the engine last a little longer between services. I would be up for anything. I am not a lazy person when it comes to taking care of my cars, but obviously being able to keep it running week to week would be nice! I think after I do get it running with everything I am just going to full commit to drag racing and weld in a roll cage and gut the interior and then buy a civic as a daily 😂
 
#37 ·
High horsepower is an exercise in diminishing returns. You'll spend 1/3 of your budget trying to hit the last 200 hp. Especially if it's a unicorn build.
 
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#40 ·
The head work you'll want to support a 1000 HP might cost another 4-6K. There are some pretty pictures running around on this forum of some premo looking head work. I'm not sure who did the work but they looked nice. Pics might be in Ryan's build thread.

There are a couple others that will do the port work, cc the chambers and valve upgrade on your heads. If my memory serves me correctly they were starting at around $2500/head (valve dependent) assuming your heads are good and there's no reason they shouldn't be. You'll of course want to use studs and likely O-Ring, there's a lot of cylinder pressure in a 1000 HP engine.
 
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#43 ·
Ryan's build thread.


Livernois also does heads either new ported heads or complete heads. I don't know how these stack up with others.
 
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#44 ·
Well, 7 months later and the build changed a little bit lol.
I'm 18 now, got a decent paying job, about 35 an hour, and honestly forgot this page existed

Ended up doing a gen two EcoBoost swap. Not a whole lot of pics from the swap since I was alone lol but it was surprisingly easy. Van makes 425 wheel on 23 psi on 93 pump gas and that's where it's going to stay. I have plans (and the block) to put an S85 in it (5.0L V10 from BMW), but as of now. I'm happy with how it is. It's getting wrapped in a week as well. Overall it's a stock engine with a custom intake, exhaust, and tune (by me lol). Wasn't trying to break any record numbers but more a one of daily driver. I'll send photos over when it's done.

Other news which doesn't relate to this, I bought a rally car! Technically my dream car. As I mentioned before, I was born in Japan, grew up a ton around Subies, and well finding a running one with a roll cage for 4k was hard to pass up.

Anyways, I've linked the one youtube vid I have on of the van along with my Instagram where I even drifted it lol!


Link Removed
 
#52 ·
Nothing too strange just an engine swap that most wouldn't have even considered. More power to bazai-8. If that's what makes you happy, go for it.
I mean that was kinda the point originally was to just have a beefed-out gen one which the van came with but the benefits of the gen 2 were kinda just something you can't really pass up. No more cooking of the intake valve, no more timing chain stretch, etc
 
#53 ·
This is beyond cool! We must see more!!

Not sure how old you were when you left Japan but any Dajiban influence here?? Or coincidence? Was captivated by a story about that scene I came across in a Road & Track years back. So funny Americans don’t cherish American vans nearly the same way!
 
owns 2015 Fjord F-1 (Fitty) Larry At
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#54 · (Edited)
I would like to note the usage of the the gen 1 turbos was needed. I got the gen 2 engine off my neighbor as he wanted to put it into his 79' F-150. He bought the engine with bad turbos out of what I assumed was just another F-150. It included ECU, Wiring harness


Dude Dajiban was the best!! That was exactly the influence! The last race I went to was in 2016 at Ebisu circuit, last time I was there was in 2019 before they shut down and it sucked hearing the news that part of the circuit had been destroyed last year. Either way yes, Dajiban was a major part of the influence, and so was my Grandpa, he was a big Subaru guy. But Japan has been a major part of my life and influenced the purchase of the Subaru rally car (linked below) and the wrap getting installed on the 15th!


Image
 
#55 ·
I would like to note the usage of the the gen 1 turbos was needed. I got the gen 2 engine off my neighbor as he wanted to put it into his 79' F-150. He bought the engine with bad turbos out of what I assumed was just another F-150. But other than that it is a full gen 2 EcoBoost swap. Like I said only a few photos, work, school, and the need to have a car was slowly creeping up on me and it really did put me in a bad place alone with a van that didn't run so there were tons of sleepless back to back nights. Either way, the van is done, looks and sounds great, and really is my pride and joy.

Probably one of my biggest accomplishments as an 18 year old and I am glad I found this page again lol
 
#57 ·
Did you keep the 6 speed? And what pcm are you using to control everything?

The question has come up a few times on how to do a gen 2 into gen 1 swap but it wasnt clear how to do it and be able to control both the 6 speed trans and dual injection.
 
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#63 ·
I promise though I'm trying to get y'all more photos. I'm in high school working a full-time job and the van has been in and out of the shop getting things done that is out of my league/ time frame. I can confidently say I will have a full set of Images of the engine bay, exhaust, intake, exterior, quite literally every single bit of work I've done to it on the 23rd. I have a photoshoot with a local magazine here in Chattanooga and hopefully, those photos can clear up some of the confusion that's been going on.

I legitimately didn't expect people to still be interested in this build but maybe that's just the pessimistic side of things in me, I promise, once the van gets out of the wrap shop, there will be content for everyone.

And, if you would like to see it, it will be on show on April 2nd, in Chattanooga at the Riverside Car Show! It'll be the first debut of the van and I'm super excited about that!
 
#67 ·
Honestly, I was kinda tired of going to car meets and shows and seeing the same ole BRZ/civic/ etc over and over again. I was really just inspired by these one-off builds and being able to show up to these places and meet new people because you literally are the only one of your vehicles there is a cool feeling.

But I seriously do appreciate it, words like that really help me keep pushing to get more done 😃
 
#68 ·
I just love the Dajban premise that a bunch of gearheads practically used these vans to transport their motorcycles to the racetrack.

Until one day - for reasons I don’t understand and yet I’m sure all gearheads could rally behind if we knew - someone said “let’s track the vans!!”

Things escalated quickly and got out of hand, and folks have been defying physics and financial prudence to soup up & deck out vans ever since in the name of a unique, zany adrenaline rush.

 
#69 ·
I just love the Dajban premise that a bunch of gearheads practically used these vans to transport their motorcycles to the racetrack.

Until one day - for reasons I don’t understand and yet I’m sure all gearheads could rally behind if we knew - someone said “let’s track the vans!!”

Things escalated quickly and got out of hand, and folks have been defying physics and financial prudence to soup up & deck out vans ever since in the name of a unique, zany adrenaline rush.

I can't even tell you how many times I've read that exact article, it's such a good look into how absolutely crazy some of those vans are and it really captures what I was going for.

On the other hand, I might as well talk about future plans for the van. There are two notable transit swaps to exist, both have very little media on them but if you dig enough you'll find them. Once Subaru is running like I said I do have the bare bones of an S85 sitting in my garage. That is a 5.0L V10 out of a 2011 BMW M5.

Now my good friend Ashley helped me mock up the beginnings of this project as her car was a huge inspiration for Transit V3. To sum it up, her 350Z's rear end is basically an exoskeleton and so will the front of my van to fit the additional 4 cylinders. This will literally be at a minimum two year's out but who knows maybe some of you will stumble upon that thread when it gets here ;)

Here is her car
Image
 
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