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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #1 (Edited)
POST 17 - starts the 2nd engine swap ?

Well i’ll start posting some pics and info about my 1981 bronco build. It started out as a rig i picked up in central calif in late 2015, had been sitting in a carport since 1990, 1 owner who died. It was full of bird nests and the mice had made some cozy airbnb hideouts. No rust, everything stock and original, 85k, orig blue plates, carb’d 302, c6, ford 9”, baby dookie brown in/out. This was a project for my son & i to do, to start teaching him how to wrench, develop some mechanical abilities & just how to generally figure things out.

Plan: go fast, keep it ugly, some mild wheeling w/ desert speed capabilities, safety & comfort.

It will end up as a turbo'd 331 stroker with a solo suspension.

This is the day i got it:
 

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81 FSB 351w turbo’d w/ ZF5 swap
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First things first, rear drums frozen - so new pads/drums, rotors & pads in fromt w/ new brake hoses. The fuel tank was empty, fuel lines all cracked. So dropped the tank & cleaned it out, new rubber fuel lines, cleaned out the carb, new plugs, wires, cap & rotor. Amazing enough after a couple cranks, it started, idle’d, & drove it around. Had to see how this stocker flexed....
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #3
It had some questionable smells, rotten tires. So gutted the interior, sprayed bed liner. Found some cheap swampers on craigslist, slapped those on, found some van seats for the front & put em in. Also son's first paint project - sanded it down, taped off the edges, and used 8 rattle cans of camo green spray paint. Another flex shot.
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #4
Heres where it starts to get fun. Found a 90 fox body mustang, pulled out the fuel injected 5.0, & was going to just drop it in. Then thought to myself - i think it needs more power.

Then took that 5.0 to a friends shop, had em throw in a 331 stroker kit with some AFR heads.

Now ive done multiple builds on various vehicles over the years, and have turbo’d a few of them - so this is when i decided that i was going to do a mild turbo build & make project FAST N UGLY!
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #6
Old 302 comin out...., new one being mocked up. I used new parts from an On3 turbo kit made for an 86-93 fox body mustang, but quickly realized that the only part that would be of use to this build was the passenger side manifold that the turbo sits on, which i had to modify to fit anyway. The drivers side manifold, crossover piping - well actually all the piping was going to be custom. For the drivers side manifold i used a shorty header from summit, cut the flange off and tig’d a v-band, and used 2” steel piping to mate up to the turbo mani on the pass side. Crossovers have flex sections to alleviate any expansion/contraction w/ the crazy heat cycles that this beast will go thru.
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #7

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #8
Front mount intercooler, tranny cooler. Even though the bronco has a decent amount of space in the engine bay, by the time all the piping goes in, hoses, electric fan, downpipe, etc....its pretty cramped in there...not as bad as a ricer tho...
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #9
People ask me...why in the world would you put a turbo in a bronco, & u cant offroad a turbo truck!
Short answer is this: because ive never seen one in an 81 FSB, and more importantly is the feeling, the sound, the torque, and the driveability is flat out insane. Anyone who has tinkered, built, or even bought a properly running turbo’d car will understand the grin that u cannot wipe off ur face when the turbo is fully spooled, the rush of air, and when the blow off valve blows off makes peoples heads turn in complete disbelief!
Offroad capability in terms of power & torque is crazy. Desert driving, mud, steep hills - no issue.
 

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ate lug
88 + 96 broncos, 96 F250
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All of my experience with turbos comes from the diesel world. In a nutshell- they are awesome :rockon

Im curious as to turbo specs, PSI, etc. Id love to one day turbocharge my 460, and i know the air requirements for a gas powered engine are different than that of a diesel, but not much more beyond that.
 

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People ask me...why in the world would you put a turbo in a bronco, & u cant offroad a turbo truck!
Sweet build, looking forward to seeing more!
You can certainly wheel with a turbo. A buddy of mine back in university built a 1st gen Toyota pickup 4x4 with a turbo'd 22R on propane... that thing was nuts! It ended up being an offroad-only machine, that he pulled around with an OBS Ford.
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #17
Well a little update on the bronco...

Got everything running great, boost @ 5-6 lbs on the dyno gave me 346hp, 425 ft lbs torque. Not bad, but should be better. Drove it about 1,000 miles, went for a re-tune, was pinging a little, tried increasing boost to 7-8 lbs, couldnt tune the ping out of it without pulling a ton of timing which resulted in less power that i originally had.

Within about a month after that i noticed the motor was consuming oil quite rapidly - no good. Well one night going to the airport, it must have had a healthy appetite and was drinking oil, & starved it.

Not happy, i ended up pulling it out & decided to go a slightly different route.

Now comes round 2!
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #18
Here comes the 351w & ZF-5 swap, of course with all the turbo stuff.

I bought an 95 e-350 off craigslist, 95k miles for $500 that has the roller 351w - 1 owner - excellent shape motor. Pulled the motor out and gave the van away to the first guy who showed up w/ a trailer.

The ZF5-s47 came from joes transmissions in PA - fully rebuilt & shipped to my door for about $2k.

Have since put the motor on the stand, swapped over the fuel rails, used the 302 upper intake w/ the 351w lower intake w/ an adapter flange, new oil pump & pan, water pump, same alternator. Turbo manifold & driver side mani swapped right over, had to modify the crossover pipe to fit as the 351w is slightly taller & wider than the 302. It’s just about ready to drop in.

Im assembling the clutch & bearings onto the tranny, flywheel to the motor today. Need to pull out the old C6 to make room for the beefy zf.

I’ll post some pics as soon as im about to drop it all in.
 

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81 FSB 351w turbo’d w/ ZF5 swap
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Discussion Starter #19
The 351 is all ready to be dropped in, just need to test fit the zf5 & install the flywheel & clutch components. Heres a couple pics..

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