6.1 intake and heads on a 5.7 build - Hemi Truck Club
 

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Old 02-18-2018, 04:18 AM   #1
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6.1 intake and heads on a 5.7 build

*****First things first hopefully I put this in the right place. If not please feel free to move.*****

This post will show everything you will have to do in order to put a 6.1 intake and heads on your 5.7 hemi.

Background:
The 4.7l in my 2003 ram quad cab went a few months back so I decided to replace it with a 5.7 hemi. After reading a **** ton and hearing how much more power you can get from the 6.1 heads and intake I decided to take the plunge. Now before everyone decides to flame me, yes I know my stock motor won't be able to take advantage of these mods. I plan on stroking and forging this motor to 6.4 and remote turboing it.

On to the project!!!

The 6.1 head do fit and clear the valves with cosmetic .075 thick head gaskets. I threw on the intake manifold and encountered my first problem. The left mounting hole for the ac compressor and the bolt hole to the left of that hole are in the way of the throttle body and part of the intake. To alleviate this I the a pair of 1/2" spacers betweend the heads and the intake. This did help a little bit however it wasn't enough to clear the ac mount. After taking a good hard look at the 3rd strike performance install kit I decided to cut those 2 hole off of the timing cover. I was originally going to remove the timing cover and mill the offending parts off however I've already put the harmonic balancer and I really don't feel like dealing with that again. Moving on my weapon of choice was a sawsall with a carbide tipped blade and a grinder with a cutoff wheel. I took off enough material to clear the throttle body. It looks like **** right now but ill go back after the mockup stage is completed.

After clearancing everything I decided I needed to make the spacers. For these I had just the right size material. I used the gaskets to mark and drill my mounting holes. After I got both of the spacer mount holes drilled and checked I moved on to the ports. For this I used a 1" hole saw and drill a square pattern, undersized of course. After I removed a majority of the material I milled the rest off for a nice finish. I'm currently in the middle of making these spacers and will update as I go.
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Old 02-18-2018, 04:25 AM   #2
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I also figured out the mount for the throttle cable.
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Old 02-18-2018, 05:53 AM   #3
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The Car/jeep front cover eliminates the need for spacers.
I like the throttle cable bracket. nice work on the spacers.
Curious why a .070 thick Head gasket? the bump in compression with the stock .028 gaskets would help take advantage of the increase head flow of the 6.1's.
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Old 02-18-2018, 06:10 AM   #4
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Well done, making needed bits and pieces is much more rewarding than paging through a catalog.
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Old 02-18-2018, 06:33 AM   #5
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The stock 5.7 c/r is around 9.63 ish with the .028 gasket and 85cc heads. The 6.1 heads are 74cc and I know my heads have been surfaced. If I used the stock gasket the heads would be sitting around 10.96c/r. With my .075 cosmetic gaskets and 74cc heads ill be getting around 9.80c/r.

That's the reason I went with that gasket.

Another thing to keep in mind is for right now I'm just trying to get this thing together. These are the parts that I have and I'm fortunate to have a mill, lathe and a steel/aluminum mig welder in my basement.
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Old 02-18-2018, 08:12 AM   #6
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Nice work!

High compression for the win though. I run 85cc heads milled three times now stock gaskets and the wrong pistons I am around 10.5-11.0 we think now and run 16-20 psi of boost without issue I saw run it!
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Old 02-18-2018, 10:04 AM   #7
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Looks great! Thanks for posting good pictures and detailed info. There are lots of posts giving some rough info about the need for spacers and such, but good pictures are worth 1000 words! I may decide to do this one day as an upgrade, I'll see I guess.
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Old 02-18-2018, 11:49 PM   #8
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Here's the update:

I got the spacers completed and also fabd a rough egr block off plate. It doesn't seem like a lot but there's over 6 hours of drilling and machining in these two spacers alone. At first I thought id rough drill the port holes out with a hole saw since slotting on a manual mill is hard on the tooling not to mention time consuming. Well turns out that hole saw really liked to gum up quickly. After dicking around with that for 2 of the 4 ports, I stacked the two spacers to save on fixturing, I decided to switch over to a 5/8" drill bit. What a life saver and boy was it clean. Afer getting a majority of the material removed I followed that up with a 1/2" 4 flute endmill. I wasn't shooting for perfection with these spacers. I can cnc another pair out later perhaps out of teflon as it can take 300°c without distorting. Maybe ill even cut in some oring grooves top and bottom to save on using two sets of gaskets.

Well that's about it for this update. Tomorrow I'll throw on the injectors and fuel rails just to see what it'll look like and get a picture or two. Ill also start working on switching the ac compressor to the left side and the alternator to the right side. Ill be doing this because that is how it is set up on the 4.7 and I really don't want to buy new ac lines. Its easier and cheaper for me to solder wires. Plus I have to make the relocation brackets anyways so no loss there.

Good night ever one and thanks for the continued support!
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Old 02-19-2018, 05:31 AM   #9
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1st set I made I drilled the four corners with a 3/8 drill and saber sawed the rest of the openings. Problem with Teflon that thick is eventfully it will keep compressing, phenolic won't compress, but it'll turn brittle.

Looks good , the 6.1 intake just makes a G3 Hemi look mean.....Love em.
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Old 02-19-2018, 06:28 AM   #10
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You doing great! I've thought about phenolic spacer. Spoke to Joe @OCP about it. The only real down side is it would rise the manifold.
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