5.4L Upper Intake

As you can see the 1995 Upper intake manifold does not fit on the 5.4L.

intknofit

To make it fit I had to extend the width by adding metal and welding it together.

54intk

Ribs were added for support.

54intksd

The channels are filled to allow for the mounting of the PI head gaskets.

The welder is Eric at Best Welding in Naugatuck, CT.

intakebtm

I filled the open area of the channels with JB Weld and I placed a gasket on top of the intake and traced the outline.

portmatch

I port matched the intake by grinding within the lines. Here is the result. As you can see we now have an opening big enough for PI heads.

intakegrind

Here is the final result after a little polishing.

intakefin

I discovered that the runners I filled were used to provide vacuum to the Fuel Evaporative Emissions System and the PCV valve. To solve this problem a hose barb was added to the back of the intake.

intakevacuum

Here is how the work was done:

Cut the intake.
Mounted the intake on the motor.
Cut and welded together sheet aluminum into an upside down "U" shape.
Spot-welded the "U"'s into place. Allow time for the welds to cool.
Welded the inside of the tube where the water runs. No other welds are on the inside of the intake.
Welded up lids to close the tube.
Took the intake off the motor and finished welding beads on the outside of all the pieces. Do not overheat the intake.
Added some aluminum sheets to extend the rib supports on the bottom of the intake.
Spot-welded the 4.6L channels that are between the motor and the intake to allow for a good seal.
Filled the remaining channel with JB weld.
Port matched the openings.
Polished the openings.
Added vacuum hose barb.

NOTE: Welding of Aluminum should only be done by an experienced welder. If heated too much Aluminum will warp.

This mod is no longer on the car see here for more info.
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