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Discussion Starter #1
First let me start off by saying that I have used the on3 kit on my 99 Cobra a while back and loved it before an expedition totaled it. Great kit and actually got a friend to buy a kit as well. With that said, I am going with the on3 kit again but this time with my 5.4 Gt. I already took off all my supercharger components and ready to install the good stuff.

It already has a forged 5.4 engine with blower cams (planning to swap to turbo cams), ported heads yada yada yada. I am also running a MM k member, arms, coil overs. I will probably have to cut and weld a new piece for the hot side since the engine is wider. This is where my questions come in.

As far as welding goes, would I have to use the exact same material on it in order for it to work or can I use any metal in there (Minus aluminum of course). Im also going to go with either 12 or 15 psi. A buddy of mine just bought 2002mustanggt's master power t70 with the 96ar housing but he will be using a 68 and is letting me have the 96 if I wanted it. Should I use it for the higher boost?

Any information would be appreciated :).
 

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as the 5.4 is wider then the 4.6 you might have some clearence issues with the headers and the frame rail. but if you dont and know they fit deff use the same mettal to extend the crossover pipe it makes it easy.

as far as the .96 over the.68 deff go with the .96 the .68 will become a restriction quickly if you have a built motor and will see boost drop off quick.
 

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Discussion Starter #4
as the 5.4 is wider then the 4.6 you might have some clearence issues with the headers and the frame rail. but if you dont and know they fit deff use the same mettal to extend the crossover pipe it makes it easy.

as far as the .96 over the.68 deff go with the .96 the .68 will become a restriction quickly if you have a built motor and will see boost drop off quick.
So you wouldnt happen to know if mild steel would work?
 

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Discussion Starter #6
you can weld mild steal to ss if thats your question. I use a 309 filler when welding ss to mild steal.
Thanks man!!! That answered my question. Now just have to get another 5.4 hardballer intake and I should be set for 15 psi. Any idea how much power that'll get me?
 
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