Full Race's "Gen 2.5" Raptor build

[full-race geoff]

We took the two big turbo trucks out and had some fun

killed the tires on the grey truck (Not sure what rubber to try next)

Meanwhile my team and I are finalizing some Gen3 and bronco / ranger projects, trying to wrap before the end of year. I’m grabbing a few hours here and there for my project.



A potential win for my Gen 3/2/1 setup is I test fitted the Gen2 AC compressor and it fits the Gen 3 block and Harmonic balancer (as well as a Gen 1 block). they all share the same bolt pattern and appear to be cross compatible. The dowels looks slightly different only. If Gen 2 ac compressor/lines does in fact fit up to a Gen 3 3.5L longblock … the remaining wildcard is knock sensor. Although that’s a big one that I may not be able to answer without hands on testing with an expert calibrator. Still
More to figure out.



a couple weeks ago I test fitted the gen2 4.88 front diff and steering rack in my gen 3 Frankenframe and it all fit perfectly. Lots of room for diff cover activities. <Spicer Dana 8.8 diff covers are on long backorder until April or May fyi>. Not sure if I’m going to weld the diff case mounts right now although I made some cardboard templates at lunch yesterday. Have so much other things to focus on currently it’s the least of my worries.



I decided to try and get my Gen 2 hubs and knuckles to fit the Gen 3 frame. This would keep the hubs/bearings/lca/knuckle changes to a minimum and get me rolling quickly however it also might be a fail I don’t know yet. FYI a Gen 3 knuckle is 0.700” taller than a Gen 2 knuckle. So I’m going to make a taller steering knuckle misalignment using Camburg UCAs and machining taller misalignment spacers.



For fun I tried 3D scanning with my iPhone. Did not work out well so back to cad, drew it up 0.700 taller and also made another variant at 0.750 and 3D printed a pair before running on the lathe. After the holiday I will cycle the susp to check bumpsteer then decide if I’m wasting time here. I don’t really want long travel and definitely don’t want dual shocks up front - They block critical access to engine and turbo



For the record: Some people online say the ball joint taper is 7 degrees - it’s actually 6.4 degrees



In other news, PRI was last week and the three raptor related updates:

Nostrum DI fuel pump debut in their PRI booth: https://www.full-race.com/nostrum-2017-2020-f150-ecoboost-hpfp DI makes more power on gasoline. I ordered one for my truck, will test it on the stock motor first


Engine builder magazine had the SI valves on display (although I’m unsure why they call them gen3 and not gen2/3): https://www.enginelabs.com/news/si-valves-and-headgames-motorworks-team-up-on-gen-3-ecoboost-valves/

GSC is releasing an all new valve spring kit. The owner Greg has a gen 2 raptor and says cams are next.

 

[full-race geoff]

Better photo of diff cover clearance:

 

[full-race geoff]

Putting here for the record; chart comparing the 3 different types of Ecoboost valves - SI, headgames, Ford


SI dominates:

 

[RaceUV]

Thanks Geoff for the awesome thread! I recently pulled the trigger on the ATI balancer mentioned earlier in the thread and figured I would try to add some value here. Attached are a few photos; one of the finished install and I also attached the part numbers for the belts that are required to run it. The ATI balancer is 4% overdriven from stock so I had to play with a few different belt sizes. I also discovered that if you’re Gen 2 3.5 has 112,000 miles like mine, the overdriven pulley makes the old accessories less than happy. I ended up replacing the water pump, decoupler pulley, idler pulley and tensioner with new Motorcraft parts. Also, another side note; on the Gen 2 stuff the crank isn’t keyed but the ATI balancer is. I was instructed by ATI to just throw a small dab of RTV in the empty keyway to prevent an oil leak. I hope this helps some of you guys looking to do the swap!

Also for Geoff,

After install I noticed a more pronounced hollow sounding knock coming from the engine at low RPM. Only happens in drive and only on very low speed light throttle. Part of me wants to says it is direct injection noise. With your experience with this balancer, did you notice anything like this? Also, any idea if ARP makes a crank bolt that will fit this engine? Is it the same size as the coyote bolt?

Thanks guys!