The first turbo Barra 240T came out late in 2002, production continued through until it's final evolution the 325T, production ceased September 2016. The power numbers, the reliability and the availability of the Barra's convinced RRS this engine swap was going to be big.
In late 2015 RRS began building a Barra powered 1984 Ford LTD, to check possible clearance and compatibility issues of the RRS coil overs, rack and pinion steering kit, the under-dash brake booster, and the 3-link rear suspension system.
In building the car RRS was able to develop a series of products that would help car builders put these amazing engines in classic Fords and Mercury's. This page show cases the products we developed and the solutions we found along the way.
Typhoon Conversion Products
Putting a Barra or FG Turbo motor into a classic Ford is the No1 engine conversion in Australia in 2019.
RRS has finished the LTD build, completed engineering and the car is used as a daily driver on full registration.
The Barra or FG motor (approx 73cm wide) it will fit into most Falcon & Fairlane engine bays except XK to XP Falcon, without modifying the engine bay, but only just. In the RRS LTD, the turbo (in stock position) cleared the drivers side shock tower by 4mm, which covers from XR to XF.
Your first choice is modify the engine or the engine bay, our choice (RRS) was create a lot more space in the engine bay.
Replacing the original front suspension with Gen7 front coil overs allowed RRS to "notch the shock towers" without reducing the structural integrity of the front of the car.
Maverick, early US falcon and XK to XP Falcon have some of the narrowest engine bays, by notching the shock towers increase room and more importantly air flow, Turbos thrive on cool air
Notching the towers meant installing the HO2 height adjustable coil-overs and an RRS brake package.
Gen7 H.O.2 RRS latest coil-over with custom geometric correction knuckle, high load Bearing Hub, light weight billet top mount, cold formed chrome silicon wire springs
RRS Sway bar custom configured available in 19,20 or 21mm
RRS Pedal Mount
You need to use the electronic accelerator with your motor. RRS has developed a simple universal flat plate pedal mount, in 2 configurations BA & FG.
RRS Gearbox Mount
RRS gear box mount cross member, the highlighted piece is if you incorporate the RRS 3-link rear suspension system into the mod motor conversion.
RRS engineer and product designer Matthew Pankau moved the battery to the boot. "Moving the battery to the boot is a bigger change than people think 18 kilos moved from in front of the front wheel to behind the back wheel".
RRS Under dash brake booster
RRS has developed the Stealth under dash brake booster and master cylinder (manual or auto left or right hand drive).
RRS has created the Trans-Am 3 link rear suspension mini coil-over system to suit 9" diffs. If you purchase the 3 link you will get the gear box mount cross member included.
The 3 link will allow use the RRS wheel speed sensor.
RRS Trans Am 3 link is the great way to complete the conversion of your classic Ford into a high performance, totally reliable, starts every time. climate controlled work of engineering perfection.
RRS has created a simple rear wheel sensor that easily mounts in the RRS 3 link setup.
Then plug into your speed sensor pick up
As RRS went through the build we modified the trans tunnel to fit the ZF gearbox, built a an unrestricted dump pipe, created A dual exhaust system, had stand alone loom built, built a speed interface to work with the original digital 84 LTD dash display, modified the sump to fit the cross-member, changed the dip stick position, put in A new hi-flow fuel sender on the tank, and modified the front lower radiator support panel to accommodate the radiator hose.
These products were too specific for the combination of 270T, ZF gearbox, and 84 LTD to make into products, but they may help with your build.
Front Sump & Pick Up
To fit a Barra to an X-series Falcon or early Mustang you will need a front sump and pick up, you can either modify your sump and pick up or use the sump from a territory to clear factory X member
The Falcon, Fairlane and early Mustang have a cross member that sits across the centre of the engine bay. The Barra of FG (except Territory) are rear sump and even the territory sump does not clear all cross members
Remapping the EMC & AMC depending on the choice of gearbox.
The Barra and FG motors are fully integrated into the car, body control module, ABS, ACM (for auto models), traction control, speed sensors, all these functions need to be hooked up, disabled or mimicked, when you take the engine out the original car.
There are many different ways to solve the wiring, at RRS we choose to fully convert the computer and loom to a stand alone function and use the ZF 6 speed automatic ACM.
The advantage with the stand alone system is the ability to use existing your dash and customise the car setup with multiple computer tunes.
The two methods RRS have tried are CAE (Castle Automotive Electrical) for remapping and building a custom loom with interface boxes to use existing dash and column, the other is Herrod motorsport using SCT flash tuner and turning off the computer security and set up tune profiles. The SCT system allows dyno setup and to customise settings to suit.
In Sydney there is a loom builder called JB Automotive Electrical.
4" Dump Pipe
Turbos love air and air flow the original exhaust on the FG is restricted 2¼" dump pipe RRS configured a dump pipe to an open 4" system to navigate past the RRS rack.
RRS Dump pipe to exhaust
Twin 2½" Exhaust
RRS has developed 4" single collector to a twin 2½" exhaust to high flow muffler for the long wheel base LTD
The lower radiator support panel needed to modified to allow the use of the Barra radiators and fans.