System BXR®

Balanced Cross Ram  Design Features  Dyno Tests  Air Flow Comparison How to Order

The BXR® Secret

The BXR® Manifold, Inc. is the first to offer a manifold with a systems design approach. The BXR® Manifold consists of 8 supply and 8 demand runners which are 18" long. The supply runner, if connected to the demand runner, will produce a 29-inch-long runner length. The runner has less than one degree of taper, which is ideal for low rpm applications. The merit of the 18-inch runner with a 2.2 degrees of taper is also well known. System BXR® uses three different types of plenum covers to connect or disconnect the supply and demand runners as desired. This allows the manifold to be tuned for any engine combination by simply changing plenum covers.

The Hi-Torque Covers®, connect the supply and demand runners providing a fixed 29-inch runner length. The BXR Manifold fitted with the Hi-Torque covers provides peak torque levels in the mid 3,000 rpm range. Torque levels approach 1.33 pound feet of torque per cubic inch engine of displacement! 400+ pound feet torque reached at 3700 rpm with volumetric efficiencies of 110%. This is accomplished while still providing peak horsepower of up to 390+ horsepower with a pump gas 5.0 liter at 5800 rpm. Just look at the results.

The standard open cover, which is known as the Power Covers®, when fitted on the BXR® 5.0L has produced well in excess of 415 horsepower and 377+ pounds feet of torque. This cover is ideally suited for applications where maximum power and performance above 4,000 rpm is desired.

The Variable-Runner System®, for BXR® utilizes a slide valve to connect and disconnect the supply and demand runners while the engine is running. This slide valve is electronically controlled based on engine rpm and is pneumatically actuated . The electronics will allow some adjustment by the end user for the switch-over point. This switch-over point will depend somewhat on the setup of the engine, typically its about 4600-4800 rpm. The variable runner system does not quite provide the same peak torque and peak power as either of the fixed covers but does give an extremely broad and strong power band. Peak torque in excess of 393 pound feet at 3700 rpm and peak power in excess of 412 horsepower have been achieved. on a pump gas 5.0L engine.

The System BXR®concept provides the end user with a manifold system which can be adapted to any engine combination. These enhancements to the BXR® design readily retro-fit to any BXR® Manifold.Some users may opt to have both types of fixed covers to allow for different performance characteristics to be achieved within the same engine by a simple 4-screws plenum cover change. This may be highly desirable for a vehicle that is both street driven and raced.

It is also worthwhile to note that relatively long intake cam duration can be used with the Hi-Torque covers and still obtain excellent low-end torque characteristics while still maintaining good low speed drivability and torque characteristics.

CARB approval is being sought for all three plenum cover designs. The certification tests are eminent. This will allow 50-state approval of the BXR Manifold and System BXR®.

BXR® Balanced Cross Ram

The BXR® Manifold design is suitable for all V8 engines. It gets its name from the 8 balance tubes crossing from the center to the side plenums. This allows each cylinder to have its own air supply. The runner length is about 18 inches from valve to runner inlet. The runners feature 2.20 degrees of taper which allows the 5.0 BXR® to have 3.8 square inches of inlet area and the 5.8 liter (351) have about 4.4 square inches of runner inlet. Typical Ford manifolds have only 1.7 square inches and no significant taper.

Additional BXR® Manifold Design Features:

• The manifold is cast from high strength A356 aluminum alloy.
• The manifold features a direct line of sight from the runner inlet to the valve.
• The manifold is approximately the same overall height as the current 5.0 and 5.8 liter manifolds (GT-40). No special hoods are needed.
• The runners are isolated from engine oil splash and coolant increasing charge density and power.
• There is a labyrinth air/oil separator to reduce oil mist carried through PCV into manifold.
• The runners have extra wall thickness to allow porting, port matching and increasing taper to six square inches area runner inlet and up to 1.5 x 2.75" at head, big enough for Yates heads. See the full-scale comparison drawing attached.
• The injectors are easily accessible for easy service and change out.
• The side plenum covers are removable for clean out and porting and are sealed with O-rings, not gaskets.
• The 5.0L manifold design allows the valve covers to be removed without the need to remove any other engine component.
• A direct drive distributor is supplied with the manifold providing dramatic improvements in the timing accuracy and compatibility with existing ignitions.
• The manifold accepts all Ford 4-bolt pattern single butterfly throttle bodies up to 90mm and retains EGR!
• The manifold will accept all OEM 5.0 and 5.8 liter emission controls.
• The manifold features extra wall thickness to allow easy installation of NOX fogger nozzles.

Dynamometer Tests with BXR® Manifolds:

Test Engine Specs  BXR + Hi-Torque  BXR + Variable Runner System BXR on Stroker 302  BXR on 5.8L

5.0L BXR® Production Sand Cast Manifold with Power Covers®

Dyno Test Results:

Current testing has demonstrated that a 5.0L V8 (306 cid 4.030 x 3.00 bore x stroke) with the specifications listed produced 417 hp @6100 rpm, 382 ft-lb torque ~ 4700 rpm and averages 364+ hp from 4000 to 6500 rpm when fitted with the production 5.0L BXR® manifold with Power Covers. The engine had over 334 #feet of torque at 3100 rpm on unleaded premium gasoline.

    Test Engine Specifications:

The above engine was run on the dyno with a stock EEC-IV and Ford Extender 42 psig fuel pressure, 18° initial timing.

5.0L BXR® Production Sand Cast Manifold with Hi-Torque Plenum Covers:

The Hi-Torque Covers were placed on the manifold on the same 306 cid used for Power Cover testing with unleaded premium pump gas.

Dyno Test Result Highlights Hi-Torque Covers:

326 ft-lb torque @ 2700 rpm

• 85% of full torque (340 ft-lb) from 2800 - 5900 rpm
• Peak torque 400+ ft-lb @ 3700 rpm
• 90% of full power (350 hp) from 4900 to 6400 rpm!
• One horsepower/cubic inch at 4300 rpm
• Peak power 390+ hp @ 5800 rpm

No special electronics or extender is required to achieve peak torque or peak power!

The Hi-Torque covers are the ideal set-up for a street car.

5.0L BXR® Production Sand Cast Manifold with the Variable-Runner Plenum Covers:

The Variable-Runner Plenum covers were placed on the manifold on the same 306 cid engine used for the Power Cover testing with unleaded premium pump gas.

Dyno Test Result Highlights Variable-Runner Covers:

• All around performance champion
• 332 ft-lb of torque ~ 2700 rpm
• 85% of peak torque (333 ft-lb) from 2700 to 6300 rpm, 3600 rpm power band!
• Peak torque 392 ft-lb ~ 3700 rpm
• 90% of peak power (370 hp) from 5200 to 6500+ rpm
• One horsepower/cubic inch @4300 rpm
• Peak power of 412 hp @6100 rpm
• 100%+ VE from 3700 to 6500 rpm

 

Testing of Prototype BXR® 5.0L Manifold on 302 Stroker 342 CID

The same 5.0 BXR® manifold with no changes to port window, injectors, fuel rails, mass air meter of throttle body was fitted to a street/strip 342 cid 8.2" deck height motor. The engine has a mild mechanical street roller cam advertised duration 288 degrees intake, 300 degrees exhaust with 0.586 intake and 0.613 exhaust lift. The heads were ported TFS aluminum, the pistons 12.5:1.  290 cm intake, 220 exhaust flow. Peak power, produced at 5800 rpm was 483 hp and peak torque of 465 ft-lb was produced at 4800 rpm. The engine had excellent low end torque, 400 ft-lb at 2800 rpm!

When the GT-40 manifold was fitted to this engine, the peak power was reduced by 43 hp. peak power was at 5300 rpm. At the 5800 rpm level, the GT-40 hp was down 75 hp! The GT-40 test was run with the same injectors, mass air meter, throttle body, ignition system as in the BXR® manifold test so that true one-to-one comparisons can be made. The same benefit found on the 5.0 was found on the Stroker 5.0 It should be noted that for this test the GT-40 was modified to straighten the inlet into the side plenum to improve its performance.

This engine was installed in a 3400lb Mustang street car with a C4 automatic transmission in a 4800 stall torque converter. On its first time out: 11.09 sec @ 120.53 mph, motor only, no power adders except the BXR® Manifold.

When the cast BXR® Manifold was installed it increased performance level by 5% over the prototype BXR® Manifold based on our chassis dyno tests. We attribute this increased performance to the effect of the rounding of the radii of the plenum covers of the cast manifold as opposed to the sharp angled plenum covers in the sheet metal prototype manifold. Also, the corners of the runners themselves were rounded in the cast manifold and the inlets of the cast manifold could be optimized for the 342 CID inlet.

Prototype 5.8 liter BXR® Manifold Testing

Air Flow Data  Additional Information

The 5.8 liter BXR® sheet metal prototype was applied to a Fontana Aluminum small block which was bored and stroked to 449 cid. This was to test the extremes of range of displacement that the BXR® could contend with. This engine produced 600 lb-ft of torque @4800 rpm and produced 601 hp @5700 rpm.'  This combination has run 10.47 see @130.58 mph with a 3300+ lb street Mustang on pump gas and with mufflers, catalytic converters and tail pipes!

Test Engine Specifications:

 

Air Flow Data:

The cast BXR® 5.0L Manifold with a stock port window increases air flow by about 17% over the stock manifold. The air velocity is 17% higher and the ram effect is increased by about 37%. There are no dead cylinders. All cylinders get the same flow within +/- 2.5% versus +/- 6% with a stock manifold giving all cylinders the same mixtures with increased air flow. No rich, no lean, no air starved cylinders. See air flow results on page 12.

Additional Information:

The BXR® Manifold is supplied with fuel rails and a crank driven direct drive distributor. Direct Drive Distributor System

Anyone who has timed a typical V8 engine has noticed that variation exists in the timing source around the desired point by a degree or two +/- from the desired value. The source of this variation is from the lash or slop in the system from the crank shaft to the timing chain to the cam shaft to the cam and then to the distributor gear. The problem is further compounded by the oil pump drive and cam wind-up and unwind. Clearly, inaccurate timing is undesirable

The ideal would be to direct drive the distributor off the crankshaft. BXR® Manifolds, Inc. has developed a direct drive distributor of this type which is compatible with all ignition systems that will work with 5.0L TFI systems. A portion of a stock distributor is modified and fitted with a precision toothed drive belt system as often seen on overhead cam engines. This belt system provides very accurate timing +/- 0.1 degree through the rpm range. All modifications to the distributor are cut from billet stock.

The mounting can be accomplished on vehicles with or without air conditioning and power steering. Water pump mount provided for cars without air conditioning. Air conditioning mount provided for cars with air conditioning includes a belt tensioner. The kit consists of a direct drive snout for the crank shaft, a modified crank 2:1 belt pulleys, toothed timing belt, mounting brackets for the distributor and the modified distributor. The distributor shaft is converted to sealed-for-life bearings and has a tool steel shaft. Testing has shown 40,000+ mile belt and pulley life.

The system is compatible with all existing TFI equipped V8 Mustangs 1986 through 93 and soon will be available for 1994-95 5.0 L and 5.8 L models as well as Lightning trucks.

Ordering Information:

Update  Important Ordering Info Additional Kits What you'll need to Order

The direct drive distributor kit is available for TFI equipped V8 Mustangs 1986 through 1993. Request additional information by fax or direct order by fax (914) 354-0859 MasterCard/Visa. Mail Orders accepted with certified check, money order or UPS-COD.

The cost of the distributor kit is $399.95 if a trade in of a serviceable distributor core and crank pulley are provided. The cost without core is $499.95 A core consists of a distributor from a 5.0L Mustang, a cast aluminum housing with ignition trigger and good oil pump drive gear and a stock crank pulley. No TFI module or cap support needed. Under drive pulleys can also be provided at the same cost or on a direct exchange basis.

 

Update:

The mass production casting of the aluminum 5.0L BXR®, Manifold has been completed. 5.0L

BXR®, Manifolds are currently available. BXR® Manifolds for 351 will be available in early 1998.

5.0L BXR® Ordering Information:

We are taking MasterCard/Visa orders by fax (914) 354-0859. Mail Orders accepted with certified check, money order or UPS-COD.

The 5.0L BXR®~, Manifold racers installation kit priced at $1995 includes:

• BXR®, Manifold with Power Covers, or Hi-Torque Plenum Covers®
• High capacity fuel rails and fuel rail extension for up to - 10 line
• Direct drive distributor system kit, AC or non-AC

Optional Emissions Kits: CARB/EPA certification applies to only complete emissions kit. (Prices are quoted for purchase with BXR® Manifold only.)

• Air Inlet Kit: $99.95 includes a 3" diameter mandrel bend, a K&N air filter, hose clamps and hose suitable for up to 75mm throttle bodies. Other inlet sizes up to 4.5" tube are available on special order basis. The low restriction air filter, K&N (RD-1450) is 8" diameter and 6" tall.
• Fuel Line Kit: $199.95 includes a 0-100 psig fuel gage, fuel regulator block, connectors, mounting hardware, Teflon paste sealant and 4 deluxe braided stainless steel Teflon -6 hoses with Ford OEM type connectors which allow a direct bolt in.
• Heater Hose Kit: $34.95 includes hoses, clamps to connect the heater and water by pass.
• Mechanical Fan Kit: $14.95 includes spacers and studs.
• Vacuum Hose Kit: $19.95 includes taps, Teflon paste sealant and hoses to complete emissions vacuum connectors.
• Oil Fill Modification Kit: $9.95 includes hose and clamps to modify the oil fill on stock Ford valve cover.
• Lengthened Engine Wiring Harnesses: $150.00 to accommodate the BXR® Manifold. $75 rebate with your old harness as trade. Harnesses are modified using Ford approved wire and connectors.

 

Other Options:

• Air Conditioning Line Kit: $139.95 includes -10 braided stainless steel Teflon hoses, adapters and fittings to allow a direct bolt in.
• AOD Kickdown Cable Kit: $7.95 includes brackets and mounting hardware for AOD transmission use with the Ford kickdown cable # F2TZ-7F-042-A. (Cable not supplied)
• Additional Pair of Plenum Covers: $149.95 includes a pair of either Power Covers for high power and high rpm applications or a pair of Hi-Torque`', plenum covers for maximum low end power. Mounting bolts are also included.
• Variable-Runner, Plenum Covers: $599.95 (Call for availability). These covers provide the widest power and torque band of all. The Variable-Runner Plenum cover option includes installation kit, electronics, wiring harness and actuation system.

 

Direct Drive Distributor Cores Wanted:

• We will purchase stock distributors and pulleys for $50 per set. Must be from '86 - '93 or '93 -'95 5.0L engines.
• We will also purchase OEM 5.0 HO engine harnesses for $50.00 complete.

What to Order: BXR® Manifold:

Fuel System  Ignition System  Air Supply Wiring Hoses  Throttle Linkage Fan  Automatic Transmission Port Matching

If you are installing the BXR® Manifolds on a race car only application, the base manifold kit which includes fuel rails and a direct drive distributor kit should be sufficient. Pure race vehicles often use after-market wiring harnesses, fuel systems, and engine-management systems so no other BXR® kits may be needed. Some Race car applications often have heaters, mechanical fans or other stock components so perhaps some of the on-road kits may be helpful.

In order for an engine to run it needs fuel, air, lubrication, cooling and spark. The discussion below will tell you what additional parts you might need to best suit on your application for the BXR® Manifolds.

Fuel System:

For race applications, the BXR® Manifolds is equipped with two fuel rails which accept 3/8ths NPT fittings to adapt to any size of fuel line from -6 to -10. Each end of the fuel rail is drilled and tapped for a 3/8th NPT fitting. Fuel to the manifold can be fed from either end of the fuel rail.

For street applications, a Fuel System Kit has been developed by BXR® Manifolds, Inc. This fuel system consists of four lines which will directly connect the original equipment fuel system of the car to the fuel rails. All fittings, lines and even a tube of thread-sealant is included in the Fuel Line Kit. The Fuel Line Kit consists of -6 lines which will supply abundant fuel for applications in excess of 600 HP. The original equipment fuel lines and pump, however, may not be able to supply sufficient fuel unless run with substantially larger pumps or boost pumps. If it is desired at a later date to further upgrade the fuel system, the AN lines and fittings which are supplied can easily be upgraded to -10 as may be required. The Fuel Line Kit also includes a fuel pressure regulator block which accepts any Ford 3-bolt regulator and appropriate fasteners are supplied with the Fuel System Kit to fasten the regulator to the fuel pressure regulator block. The fuel pressure regulator block is bolted to the original bolt holes which held the mass air meter on the original installation. A 0-60 psi pressure gauge is included for ease of checking fuel system pressure in monitoring fuel system performance. The fuel lines provided are designed to connect with the original double O-ring fuel line fittings as supplied in the original equipment installation. The lines are premium, aircraft-quality, braided stainless steel Teflon hoses.

Ignition System:

The BXR® Manifolds requires the relocation of the distributor in the 5.0 liter engines. The direct drive distributor system provides bracketry and a drivebelt system to connect and directly drive the distributor off the crank shaft. There are two basic kits utilized for the BXR® Manifolds system.

The Direct Drive Kit for vehicles without air conditioning mounts the direct drive horizontal mounting bracket to the water pump. A drill and tap is provided to enlarge the top two water pump bolt holes from 5/16ths to 3/8ths. Stainless steel studs are provided to thread into these water pump mounting bolts and the direct drive horizontal bracket is positioned to hold the vertical bracket which holds the distributor. A toothed belt of approximately 32 inches in length is used to drive the distributor off the direct drive pulley which is attached through the crank snout extension mounted to the crank shaft pulley. Because of the short length of this belt system, no auxiliary tensioner is required.

The Direct Drive Distributor Kit for vehicles with air conditioning includes a different horizontal bracket and a belt tensioner system. The direct drive belt is approximately 42 inches long and has a belt tensioner which holds constant tension on the belt through the life of the belt. To date, no one has ever worn out the BXR® Direct Drive Belt, pulley or distributor.

The crank shaft pulley, crank snout extension and crank shaft pulley is identical in both kits. The crank shaft pulley is mounted via four 1 2-point high-strength bolts to the crank shaft dampener.

The original equipment wiring harness has sufficient length to allow the TFI module on the distributor to be directly plugged into the original wiring harness. An extra long MotorCraft ignition wire is included in each kit for the #4 cylinder. The remaining ignition wires can be used for the installation.

Air Supply to the BXR® Manifold

An air-inlet kit has been developed for the BXR® Manifolds. It uses a K&N #KD1450 filter which is 8 inches in diameter and 6 inches long and provides ample air filtration for 5.0L and stroker 5.0L liter engines. A mandrel bend, 3-inch aluminum tube, is provided along with appropriate hoses to connect the air inlet kit to the throttle body. This Air Inlet Kit is suitable for use with throttle bodies up to 75 mm. Additional larger air inlet tubes and hoses are available on a special order basis.

Engine Wiring Harnesses

For race applications the OEM sensors may or may not be used. For that reason the base kit is not provided with an extended wiring harness. However, for street use where the EECIV computer is used, the wires have to be extended for the repositioned throttle body EGR throttle position sensor. In order to make the installation easy, BXR® Manifolds, Inc. has developed an OEM-quality wiring harness which is extended to accommodate the relocated components. This makes the installation of the wiring harness as easy as the original-equipment wiring harness. Since the wires are extended, this harness is still usable with the stock manifold if so desired at a later date. Wiring harnesses are remanufactured to OEM specifications prior to shipment. New harnesses are under development and will be available at a higher cost.

Engine Coolant Heater Hoses

In many race applications, the heater in the vehicle is not used, for purposes of saving weight. However, in street-driven vehicles a heater is desired. BXR® Manifolds, Inc. has developed a simple, low-cost kit of molded hoses which allows the ready connection of the heater to the hot-water outlets on the engine. The stock hot-water manifold is modified and is used in connection with these hoses.

Throttle Linkage

The original-equipment throttle cable and bracket is retained with the BXR® Manifolds. However, an adapter plate is provided to mount the original-equipment cable bracket to the BXR® Manifolds. The user is required to drill one additional quarter-inch hole in the bracket to allow mounting. A suitable drill is provided. All fasteners are provided to mount the throttle-cable bracket to the manifold. A special throttle cable pivot is provided to connect the throttle cable to the end of the throttle-body bell crank which normally is used for the automatic transmission. This pivot is provided with a base kit.

Mechanical Cooling Fan Modification Kit

If an electric cooling fan (which is a desirable feature in the Ford Mustang) is not used, one can still the mechanical fan. BXR® Manifold, Inc. developed an inexpensive kit to allow the use of the mechanical fan with the BXR® Manifold. This kit moves the fan forward, closer to the radiator. A spacer and studs and nuts are provided. The fan shroud must be notched for the air-inlet tube and the center rod on the back side of the radiator must be removed for additional fan clearance. This system provides a lower cost alternative to converting the vehicle to electric fans and may be desirable in some road-race applications where a mechanical fan is still desired. Oversized radiators may not allow this mechanical fan kit to be used unless the radiator is located further forward. Otherwise electric fans must be used. AOD

Automatic Transmission Applications

Since the throttle body has been moved to the front center of the engine, the stock kick-down cable cannot be used. Ford Part Number Ford # F2TZ-7F-042-A must be used, not included with kit. BXR® Manifolds, Inc. has developed a simple kick-down cable bracket which is mounted to the throttle-body bell crank. This is mounted via two thread-forming screws with jam nuts which provide a secure mounting of the automatic transmission cable pivot. The throttle cable bracket also must be modified for the new cable. (Hole in the bracket for cable must be filed square.) BXR® Manifolds, Inc. is currently investigating the possibility of supplying modified throttle cable brackets for this installation.

Port Matching

The BXR® Manifolds as cast will port match with virtual perfection to the stock head. After-market heads with large ports will require port matching for optimal results. Port matching requires significant skill with machine shop tools such as die grinders and milling machines. If you are already familiar with this operation, the BXR® Manifold port matches are easily obtained due to the line-of sight through the runners to the cylinder head port. If you are not familiar with this operation, you should seek professional assistance. The demand runners to the head taper strongly at the cylinder head end of the runners to allow for easy porting. The manifold is manufactured to require porting no more than 3 inches into the runner. This permits the area to be ported to be easily reached with standard porting tools.

 

AIR FLOW COMPARISON