04-08 Gotts Mod
I couldn't find a how-to for the Gotts mod on this forum yet so I'll make one for everyone that hasn't seen it or done it before.
I did this on my 08 4.6L but the process is the same for the 5.4L except more pipe is needed than what I used and you just need a 3" hose clamp instead of a fernco.
For those of you who don't know, the Gotts mod takes your factory fender inlet of ~2" and increases it to 3" for better throttle response and better flow at WOT.
2' piece of 3" PVC (white) plumbing pipe or ABS (black) pipe, depending on your area's availability
3" plastic to 3" plastic rubber "fernco" connector if you have a 4.6L, 3" hose clamp if you have a 5.4L
screwdriver with either a slotted tip or 5/16 hex tip, both can be found on a 6in1 combination screwdriver
grinder with a grinding pad, not a cutting wheel
vise or some other way to secure the pipe while grinding
paper, sharpie and scissors to make the template
First step is remove the first say 2' of the stock air intake from the fender towards the engine for the 4.6L and from the fender to the air filter on the 5.4L
Second step is to remove the fender piece from the intake parts you just removed
The next few steps are the same for both engines. Take a small piece of paper and a sharpie to your truck. Hold the paper to the hole in the fender where the old piece went through and trace it onto the paper. Cut it out with scissors and check with the fender to confirm size. Recut as needed.
I also took the rubber fender seal off the intake piece to confirm size also.
Then take your template to the end of the pipe and trace it. Should look like this.
Measure and mark lines 2" from the end of the pipe, that is how much will be ground off to insert into the fender. I found it easy to ratchet strap the pipe to a bench for the grinding phase, it held it tight but allowed for easy rolling to keep grinding.
Grind the outside of the pipe down until your sharpie line is gone. Make sure to keep moving the grinder so you don't go too deep and cut into the pipe. Not a big deal if you do, you just want to keep everything as intact as possible. Looks like this when grinding is completed.
Test fit and regrind if necessary. I got mine to fit first time because my template was pretty accurate.
Next, mock up and measure how much pipe you actually need to complete the intake.
Now for connecting the pipe to the intake.
For the 4.6L, you use the fernco and tighten it to the other half of the air filter canister and your new pipe. I found it easiest to put the pipe in the fender, fernco on the pipe, then attacth the filter canister to the fernco and tighten the clamps. Looks like this when completed.
The 5.4L uses a 3" hose clamp on the intake end and then the pipe just fits into the fender snugly by itself.
You can paint the new PVC pipe with black paint if you choose to, I didn't since not much of it even shows anyway.
Last step, or for some of you - in between steps, grab a beer and enjoy your new mod which cost less than $15.
***All 5.4L photos were used from a thread made by JackandJanet on the F150online.com forum. ***