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Discussion Starter #1
Just bought an Explorer upper and lower and am cleaning it up for an upcoming engine build. I have a couple questions.
I took a wire wheel and some stripper to the upper. I was going to repaint it but i really like the way ot looks bare. I’m far from done but was thinking I might just polish it up and spray some clear coat on it to keep it from tarnishing. Good idea?

Any other suggestions or tips? Were these intake painted from the factory or were they bare? I currently have the stock HO manifold on the car and when I did the build a few years back I just cleaned it up and painted it aluminum cast coat. It’s held up pretty well.

The vacuum tubes on the upper....can these be removed for cleaning/polishing? They are totally in my way for cleaning up the underside, and if they can be removed then possobly I could replace the crazy shaped front tube for a shorter one for my purge cannister.

And finally, could someone measure the total height of their stock HO manifold for me? I had to shave the top of my lower HO for hood clearance (Miata conversion). I need to calculate how much I need to shave off this new setup. It has to fit under the stock hood.

Thanks y’all.
 

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Where are you located? I have an Explorer upper that I paid to be powder coated, and it's closer to "chrome" than the silver I was after. I spent a lot of time grinding and filing away the casting lines/marks, and I removed the mount/protrusion that holds the throttle cables. So mine looks very good, but it's not what I had in mind for my newest plan for it. I'm aiming for an OEM grey or similar grey, and was going to paint over this if no better idea comes up.
 

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Leave the upper bare, natural finish, that chrome stuff is retarded, chrome is for harleys and hot rods which are both lame. While you have it apart send the lower to TMOSS to get ported.
 

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Discussion Starter #4
Ya it's going to Tom once the machining is done. Still looking for answers on those questions if anyone has ideas.
Thanks.
 

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I can try to answer 3. Yes, they are factory painted. Yes, you will need to clear coat or paint or they will oxidize quickly and look like crap. AFAIK all the fittings can be removed since they're threaded in, but you have the intake so this should be obvious. (edit: looks like some are threaded some are pressed). Can't help you with height.
 

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Discussion Starter #6
Cool, thanks for the info. I don't see obvious signs of the tubes being threaded on this one but maybe I'll try putting some vice grips on one and see. If they're pressed in maybe heating them up would expand the holes enough to pop them out.
Thanks.
 

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Cool, thanks for the info. I don't see obvious signs of the tubes being threaded on this one but maybe I'll try putting some vice grips on one and see. If they're pressed in maybe heating them up would expand the holes enough to pop them out.
Thanks.
Yeah, I just looked at some pics and there's only one threaded, but looks like only on the EGR upper. Same on stock fox upper which was what I was remembering (threaded T fitting) The rest, which would be the ones in your way, look to be pressed in.
 

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Use a propane torch to heat the manifold and vise grips on the tubes. Drill and tap for plugs or fittings.
 

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you only need to use heat to remove the press ins if you are going to re-use them. you can do it cold too if you are careful not to crush the tube. heating make re-insertion easier. use a grinding wheel to champfer the tube end, then tap it into the hole just far enough to hold - heat the upper and tap the tube back in with a small hammer.
 

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I just recently did the seals on my intake and while it was off painted it.

I have a stock 5.0 intake though so it may be different, but I just sanded around the tubes and then taped them off.

Turned out really nice.

I used engine enamel on it that was pretty dead-on for the factory color... turned out great :)
 

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I used aircraft stripper on my stock upper. Took a few applications but minimal elbow grease. Then I taped all the lines underneath and painted it.
 

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I used Citristrip to peel the old paint off my intake. It's slower than aircraft stripper, but i had time, and it allowed me to do it in my basement slop sink. I basically rubbed the manifold down with citristrip, bagged it in a trash bag (to keep it moist) and let it sit a day or two.

Before i began, i pulled ALL of the vac fittings out of the manifold. My plan was to drill and tap new fittings based on what I needed.

After a day, it looked like this. I scrubbed it down, and repeated one more time



Then, i chopped off the little nub on the plenum, and started sanding it down with a flap disk to remove a lot of the casting blemishes




Pulled out all the vac fittings and drilled and tapped new fittings for what i needed (brass fittings have been replaced with stainless)



Cleaned up manifold with casting mold lines removed after priming


Also restored the intake plaque


Completed product. Duplicolor Cast Coat paint.



I also had the lower ported by Tmoss's son. A 75MM EGR spacer and converted 65MM Explorer TB are also part of the intake. Probably more time and money into an explorer intake than most people would bother with. I wanted the stock look. It's been sitting on my shelf for over a year now. I have a 1993 cobra intake on the car, so when i pull the engine out this fall to rebuild, this will finally go on the car.
 

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I got a measurement for the oem upper and lower intake.I placed a level on top of each piece where I felt each intakes tallest point was then I used a square and measured up to the level on each intake.Im terrible with a tape measure/ square so use the pics for reference please.
For the upper,I got one mark past the 5.5 mark.
For the lower,I got 4.5
So its a little over 10" for the height with both intakes combined.
P.S.- Im not sure why the pics are displayed in a sideways/landscape view??They're in portrait view on my phone,otherwise I would have edited and rotated them to portrait view.Just turn the phone sideways I guess to view.
 

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Discussion Starter #18
Awesome. Thank you both for those measurements. It helps me a lot since my car is still in storage.
Cheers.
 

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Discussion Starter #19
I found a shop that will blast and powdercoat my upper and lower for $100. That’s cheaper than buying the paint stripper and the paints, and I don’t have to do the grunt work.
I do have more questions about the vacuum fittings. I see LMR sells the vacuum branch that feeds the egr, for and firewall vacuum tree. Does anyone sell the short front facing tube? The one on my explorer upper is way long and has a weird upward angle that won’t look right in my engine bay. Thanks.
 
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