With so many hot, supercharged Lightnings and Harleys on the scene, the aftermarket manufacturers and speed shops continue developing new products to maximize the performance and fun factor of these factory hot rods. Recently, Ford Truck Performance had the opportunity to test and evaluate a number of these new parts on some of our trucks. This story summarizes the initial installation of the parts and some quick results from the latest gear in the marketplace.
We first visited Ken Bjonnes and Brandon Alsept, owners of MD Motorsports and Apten Performance, a Cincinnati-based speed shop specializing in all sorts of high-performance late-model vehicles, but especially Modular-powered Fords. They handled the install and chassis dyno-testing of the Dynatech headers, Johnny Lightning Performance aftercooler water reservoir, and Afco Heat Exchanger upgrade. Justin Burcham of JPC Racing, Glen Burnie, Maryland, handled the installation of the Reichard Racing Belt Tensioner. With hundreds of customers from around the country, these guys have seen good parts and some not-so-good parts. Their experience will keep our readers on the cutting edge of technology as we test the best the aftermarket has to offer.
AFCO Double-Pass Heat Exchanger with Fan Kit
PN 80249N-FS $749.95
We all know that keeping the big, supercharged 5.4 filled with cool, dense air is critical to maximizing the power potential. Once you take boost levels over stock, you face the harsh reality of your pride and joy quickly becoming heat soaked, killing power and potentially costing you a critical race. This is especially true for street-driven Lightnings that don't have the benefits of a cool-down period like the race-only trucks. Aftermarket manufacturers offer all sorts of different ways to keep the intake track cooler, but nothing comes close to investing in a bigger, more efficient heat exchanger.
Located at the very front of the truck, the heat exchanger catches outside air, while circulating intercooler fluid is cooled off after flowing through the intercooler. This vital piece of the engine system can max out quickly under full-throttle runs or just regular street cruising. It's like a radiator or transmission fluid cooler for the intercooler fluid.
 Comparison of the factory...  Comparison of the factory heat exchanger versus the Afco one. |  Quality finish and fit are...  Quality finish and fit are a part of the Afco heat exchanger's traits. |  The heat exchanger hides behind...  The heat exchanger hides behind the lower valance. It gets plenty of air running over the body's fins to cool down the intercooler fluid. |
The folks at Afco recently told us about their answer to this problem: the new Pro Series double-pass heat exchanger. It utilizes Afco's new dual pass-through design, which promises to enhance coolant flow and thermal stabilization. Its Pro Series heat exchanger takes this technology one step further, combining the increased efficiency of its heat exchanger with an optional pair of high-output fans to draw more air through the it, dramatically decreasing inlet temperatures. The fans generate 800 cfm across the heat exchanger, and Afco claims a 40-degree drop in inlet temps.
We noticed the high quality of the welds on this unit right away. All associated hardware was present and accounted for, and full-color step-by-step directions were included.
Our installation at MD Motorsports went smoothly. In less than 20 minutes, the heat exchanger fit easily in the space where the less efficient stock unit once resided. The wiring for the fans takes some time, but they go a long way toward keeping your high-boost Lightning cooled.
AFCO Racing Products
Dept. FTP
977 Hyrock Rd.
Boonville, IN 47601
(800) 632-2320
www.afcoracing.com