DIY Network

1962 Fort T-Bird: High-Performance Engine Head From "Classic Car Restoration" episode DCR-305

The 1962 Ford Thunderbird sports roadster.

The T-bird's engine has had the distributor, carburetor, manifold and cylinder heads removed in preparation for installing some new performance parts. In this segment, the new high-performance cylinder heads get installed, and the rocker-arm assemblies are adjusted to accommodate the performance parts.

Materials:

Cylinder-heads kit and torque-spec sheets
Standard automotive tools (socket wrenches, extensions, combination wrenches, screwdrivers, nut-drivers, etc.)
Torque wrenches
Air compressor and impact wrenches (optional)
Jack and jack-stands
Brake cleaner

Safety Equipment:

Work gloves
Safety glasses or other eye protection

Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.

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Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

High-Performance Cylinder Heads

In this segment, we add more "thunder" to our Thunderbird 's 390 cubic-inch V8-engine in the form of some aluminum cylinder heads. While there are a variety of aftermarket aluminum heads available for the Ford 390 motor, we chose a set of Edelebrock Performer RPMs©. They're 20 pounds lighter than the cast-iron heads. They also have larger intake and exhaust ports (figure A) which allow the engine to "breathe better." The stainless steel valves (figure B) are larger than stock, and they also include hardened valve seats on the intake and exhaust seats. That means you don't have to worry about unleaded fuel.

Figure A

Figure B

Steps:

• Before installing new cylinder heads, it's first necessary to install new cylinder head gaskets. Whenever installing any gasket, carefully inspect it to see if there's any kind of instruction printed on it. In our case they are marked on one side with "front" to ensure proper orientation on the car. Installing the gaskets improperly could result in engine failure. Since these are perma-torque type gaskets, there's no need to spray them with any kind of a lacquer. These gaskets are ready to go. Once you've determined proper orientation, simply position the gasket on the block (figure C).

• Once the gasket is installed, make certain that the bottom surface of the new cylinder head is clean and free of debris, and carefully lower it into position (figure D), seating it in place on the head dowel-pins.

  Figure C

  Figure D

  
  
• To clamp the new cylinder heads to the block, avoid relying on the old bolts. Instead use new ones. And to keep them from galling in the block, apply some thread-sealer compound to the threads and hardened washers underneath the shoulder of the bolt (figure E). These will keep the bolt for galling the aluminum as they're torqued down. Install the bolts by hand at first. Then go back and torque them to spec.

• Cylinder heads need to be torqued down according to a specific pattern (figure F) using a torque wrench. In the case of these aluminum heads, because they're made of a soft alloy (rather than harder cast-iron), we use three torque-steps instead of the usual two. There are long bolts and short bolts. Torque-tighten at 70, 80 and 90 on the long bolts, and 60, 80 and 90 on the short ones. (A torque-spec of 90 is the final, full torque load.)

  Figure F

  
  
• Now according to our Ford factory specifications, we start at the center and work our way out. So with our torque wrench set at 60 pounds, we go to the bottom center bolt, and begin (figure G). Torque the bottom bolt down the first step of 60 foot-pounds.

• Next, set the torque-wrench to 70 foot-pounds and torque the top-center long bolt (figure H). Continue following this process, following the torque specs carefully, until all of the bolts are tightened to the proper spec.

  Figure G

  Figure H

  
  

  	Figure I
  	Figure J

With the cylinder heads installed, the next step is to adjust the rocker-arm assemblies. The manufacturer of our high-performance cylinder heads recommends mocking up the valve train to insure proper valve-tip to rocker-arm-tip alignment. As seen in our in our rocker-arm mockup, there is a slight misalignment on every intake rocker (figure I). That's because the manufacturer of these heads moved the intake valves outboard slightly to get better flow. There's a relatively simple adjustment that will fix this.

The solution is to disassemble the rocker shaft assembly and add a 60/1000-inch valve-spring shim (figure J) to re-establish proper alignment between the rocker and the tip.
With our rocker arm alignment corrected, we can get ready to install the high-performance aluminum intake manifold. In the segment that follows, both the new manifold and the newly adjusted rocker-arm assembly are installed on the T-bird.

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books

Thunderbird Restoration Guide, 1958-1966 (Motorbooks International Authentic Restoration Guides)
by William Wonder
Published by Motorbooks International, June 1997
ASIN: 0760303908
To order this book from Amazon.com, click here.

Illustrated Thunderbird Buyer's Guide (Motorbooks International Illustrated Buyer's Guide)
by Paul G. McLaughlin
Publisher: Motorbooks International (July 2000)
ASIN: 0879388706
To order this book from Amazon.com, click here.

Edelbrock Performance Products
Website: www.edelbrock.com

GUESTS :

Keller Wallace
Keller Wallace Street Rods
Volunteer Street Rod Association
Knoxville, TN