How-To: IAC Restrictor Plate (aka Beer Can Mod) & Oil Separator Bracket

Harley#356 · 11-21-2007, 01:29 PM

Harley#356’s How-To’s

IAC Restrictor Plate (aka Beer Can Mod) & Oil Separator Bracket

Purpose behind the Mod:
When you rev your truck up, it usually takes a few moments for the RPM's to drop all the way down. They usually hang high then slowly come back down. The "Beer Can Mod" restricts the IAC valve openings, letting the RPM's drop down quicker when you rev the truck. This doesn't add/hurt performance or mileage, its just simply a mod free mod for sound and to get rid of the annoying hangup on RPM's when revving the motor up. Also, rather than having a restrictor plate under the IAC and a oil separator bracket on top of the IAC, I combined both into one on this mod.

Need:
-Beer Can (soda can will work but thats no fun lol) or thin aluminum plate
-Black RTV Sealant

Tools Needed:
-8 mm Socket & Ratchet
-Marker
-Tin Snips
-Hammer (for optional Oil Separator Bracket Provision)
-Vice (for optional Oil Separator Bracket Provision)
-Drill & Bits
-File

Parts:

Either kick back a beer/soda, or find some thin aluminum plate. I used some 1/16th" aluminum engraving plate. Thin enough its easy to work with, thick enough its sturdy for the oil separator bracket.

Install:

-Use the old IAC gasket to make a template on the new aluminum. Either just the shape of the IAC for the restrictor plate, or extend it out for a provision for an oil separator bracket as seen in Photo # 1.
-Cut the plate out with tin snips
-If you're doing the oil separator bracket provision, put the plate in a vice, and use a hammer to slowly work a 90* bend in the metal as seen in Photo # 2. I used a urethane headed hammer to keep the metal from getting dinged up.
-Mark & Drill your holes, use the IAC valve for sizing on the bolt holes, then for the restrictor holes, I'd say make them between 1/4" and 3/8" in diameter. The smaller they are the quicker the idle will drop back down, but if you go too small you could have idle/stalling issues when getting out of the throttle quick. 3/8" is a good balance point as seen in Photo # 3.
-File edges down with a file or dremel (obviously not needed if you're just doing the beer can version) as seen in Photo #4.
-Sand with 80, 100, 220, 400, 600, 800, 1000, 2000 then hit with Never Dull if you want to polish the bracket as seen in Photo # 5 & 6.
-Reinstall with separator plate sandwiched between IAC and plenum as seen in Photo #7 & 8. Can reuse the factory gasket on one side then use RTV on the other. Its not needed since it shouldn't leak air anywhere, but it never hurts to be safe. Mount up your oil separator if you made a mount for the bracket.
-Fire the truck up, rev it up and check for idle/stalling issues. They shouldn't be there with a 3/8" hole, but if they are just open the hole up a bit and it should solve it!

PHOTO # 1: Old Oil Separator Bracket, Restrictor Plate, & Template for new all-in-one restrictor/bracket:

PHOTO # 2: 90* Bend for Separator Bracket Provision:

PHOTO # 3: Holes Drilled:

PHOTO # 4: Edges Filed:

PHOTO # 5: Polished:

PHOTO # 6: Polished:

PHOTO # 7: Installed:

PHOTO # 8: Overall Shot:

fepony · 11-30-2007, 11:44 PM

I'll do one tomorrow and get it on brfore the retune. I'm going to split the difference and go 5/16 dia. holes...i haven't even looked at that part since i got my truck back...not sure what's up with it..

Krix330cic(NJ) · 12-09-2007, 08:02 PM

Josh, can you make me a pattern on construction paper, and mail it to me?

Im going to crank out a ton of these outta gasket material, and hook the guys up for free with them.

chupac · 12-09-2007, 09:11 PM

Very nice combo mod. I'll be doing this one when I do an oil separator. I did 1/4" holes on mine and have only had it stall once. That was after sitting outside in 30* weather all day and not getting a good warm-up before driving away.

C Dillon Go · 12-09-2007, 11:47 PM

Great job Josh!!

'02HD#3982 · 12-10-2007, 12:01 AM

Quote:

Originally Posted by Krix330cic(NJ)

Josh, can you make me a pattern on construction paper, and mail it to me?

Im going to crank out a ton of these outta gasket material, and hook the guys up for free with them.

Go to a mechanic shop and see if they have any old motors laying around.My uncle had a 4.6 at his shop,I took the IAC off of to make mine(for my '97).Does anyone know if a 4.6 and s/c 5.4 use the same IAC?I can get a bunch of aluminum plates from work that measure approx 3.5x3.5(about 1 mm thick)

Harley#356 · 12-10-2007, 06:17 AM

krix I'll see what I can do. if somebody has their IAC off though with a gaskets thats still good, it'd be a little easier for them to go off that than me trying to go off the IAC and measure out the holes, etc. cuz I never got a gasket with mine to begin with

Krix330cic(NJ) · 12-10-2007, 09:27 AM

Yea, id pull mine off and get crackin', but the trucks not in my garage.

'02HD#3982 · 12-10-2007, 10:07 AM

I have the stuff to do it,,,I should have my plate done today.Bought 3 "make-your-own tstat gasket cards.I'll mark,cut,and drill everything today.Let me know if you still need one.

If you have a good parts store there,,,the FelPro # is 71216

Krix330cic(NJ) · 12-10-2007, 12:04 PM

Quote:

Originally Posted by '02HD#3982

I have the stuff to do it,,,I should have my plate done today.Bought 3 "make-your-own tstat gasket cards.I'll mark,cut,and drill everything today.Let me know if you still need one.

If you have a good parts store there,,,the FelPro # is 71216

Yes, if you wouldn't mind. Just something I can use to trace this out on the gasket material.

'02HD#3982 · 12-10-2007, 01:18 PM

Used 11/32 holes for my '97,,,no stalling.Idle drops ALOT FASTER.Used to rap it up,,and it would stay around 1500 for a few seconds then creeeeep down.Now it just falls straight to idle.Me likey!!!!!

Krix330cic(NJ) · 10-04-2008, 01:06 PM

Quote:

Originally Posted by '02HD#3982

I have the stuff to do it,,,I should have my plate done today.Bought 3 "make-your-own tstat gasket cards.I'll mark,cut,and drill everything today.Let me know if you still need one.

If you have a good parts store there,,,the FelPro # is 71216

About to do this.. like right now!

I believe I did get one from you, so all I need to do is smear some RTV on the one side (other is peel back adhesive), and drill my hole sizes?

Just want to be sure this wasn't just a pattern, and that it is the actual gasket material.

THANKS!

Krix330cic(NJ) · 10-04-2008, 08:10 PM

Did it.

Made out of aluminum, and went with the 3/8".

Didnt notice much, but it was nice to work on the truck today, then take a ride down the Parkway.

'02HD#3982 · 10-04-2008, 09:32 PM

I just used the factory gasket on one side(stuck to the intake on both,the '97 and the 5.0 Cougar I have now),,and the FelPro on the other.

Krix330cic(NJ) · 10-04-2008, 09:35 PM

Ah, that was my plan just after typing my other reply... but then I got my 3yr old involved, to let him try drilling the holes.

Needless to say, it was a little oblong, lol.

Had plenty of aluminum, so we just went from there.

Worth the laughs / time spent fartin around with him.

11-21-2007, 01:29 PM	#1 (permalink)
Harley#356 Worlds Fastest HD F150!!! Paid Member Join Date: Jan 2003 Location: Week-Philly; Weekend-Souf Jerz Posts: 23,527 NHTOC member #: 3 View this user's gallery iTrader: 0 / 0%	How-To: IAC Restrictor Plate (aka Beer Can Mod) & Oil Separator Bracket Harley#356’s How-To’s *IAC Restrictor Plate (aka Beer Can Mod) & Oil Separator Bracket* Purpose behind the Mod: When you rev your truck up, it usually takes a few moments for the RPM's to drop all the way down. They usually hang high then slowly come back down. The "Beer Can Mod" restricts the IAC valve openings, letting the RPM's drop down quicker when you rev the truck. This doesn't add/hurt performance or mileage, its just simply a mod free mod for sound and to get rid of the annoying hangup on RPM's when revving the motor up. Also, rather than having a restrictor plate under the IAC and a oil separator bracket on top of the IAC, I combined both into one on this mod. Need: -Beer Can (soda can will work but thats no fun lol) or thin aluminum plate -Black RTV Sealant Tools Needed: -8 mm Socket & Ratchet -Marker -Tin Snips -Hammer (for optional Oil Separator Bracket Provision) -Vice (for optional Oil Separator Bracket Provision) -Drill & Bits -File Parts: Either kick back a beer/soda, or find some thin aluminum plate. I used some 1/16th" aluminum engraving plate. Thin enough its easy to work with, thick enough its sturdy for the oil separator bracket. Install: -Use the old IAC gasket to make a template on the new aluminum. Either just the shape of the IAC for the restrictor plate, or extend it out for a provision for an oil separator bracket as seen in Photo # 1. -Cut the plate out with tin snips -If you're doing the oil separator bracket provision, put the plate in a vice, and use a hammer to slowly work a 90* bend in the metal as seen in Photo # 2. I used a urethane headed hammer to keep the metal from getting dinged up. -Mark & Drill your holes, use the IAC valve for sizing on the bolt holes, then for the restrictor holes, I'd say make them between 1/4" and 3/8" in diameter. The smaller they are the quicker the idle will drop back down, but if you go too small you could have idle/stalling issues when getting out of the throttle quick. 3/8" is a good balance point as seen in Photo # 3. -File edges down with a file or dremel (obviously not needed if you're just doing the beer can version) as seen in Photo #4. -Sand with 80, 100, 220, 400, 600, 800, 1000, 2000 then hit with Never Dull if you want to polish the bracket as seen in Photo # 5 & 6. -Reinstall with separator plate sandwiched between IAC and plenum as seen in Photo #7 & 8. Can reuse the factory gasket on one side then use RTV on the other. Its not needed since it shouldn't leak air anywhere, but it never hurts to be safe. Mount up your oil separator if you made a mount for the bracket. -Fire the truck up, rev it up and check for idle/stalling issues. They shouldn't be there with a 3/8" hole, but if they are just open the hole up a bit and it should solve it! PHOTO # 1: Old Oil Separator Bracket, Restrictor Plate, & Template for new all-in-one restrictor/bracket: *PHOTO # 2: 90 Bend for Separator Bracket Provision: PHOTO # 3: Holes Drilled: PHOTO # 4: Edges Filed: PHOTO # 5: Polished: PHOTO # 6: Polished: PHOTO # 7: Installed: PHOTO # 8: Overall Shot: __________________ ~2000 Harley Truck # 0356 of 8197~*------Built: May 18th, 2000------Bought: July 3rd, 2000------ Worlds Fastest Harley Truck PERIOD - 10.91 @ 126.35 - 10/31/08**Worlds Fastest Eaton Powered HD Truck - 12.19 @ 112.48 - 11/17/07* Photo Gallery~Email:joshv_85@yahoo.com~AIM:harley0356 NHTOC# 3

11-30-2007, 11:44 PM	#2 (permalink)
fepony Moderator Charter Member Paid Member Join Date: Feb 2003 Posts: 7,378 NHTOC member #: 22 View this user's gallery iTrader: 0 / 0%	I'll do one tomorrow and get it on brfore the retune. I'm going to split the difference and go 5/16 dia. holes...i haven't even looked at that part since i got my truck back...not sure what's up with it.. __________________ JLP shortblock, Stage 3 heads and cams, 2.3 Whipple w/3" upper and 4# lower.Ba2800, Accufab, Pacesetter LT's, 60#inj, twin 255's, LFP efan, PI 2600 stall.

12-09-2007, 11:47 PM	#5 (permalink)
C Dillon Go Smiles per Gallon not MPG Paid Member Join Date: May 2006 Location: Miles Away From Ordinary Posts: 2,900 NHTOC member #: 461 View this user's gallery iTrader: 0 / 0%	Great job Josh!! __________________

12-10-2007, 10:07 AM	#9 (permalink)
'02HD#3982 Registered User Join Date: Nov 2003 Location: Ks Posts: 2,650 View this user's gallery iTrader: 0 / 0%	I have the stuff to do it,,,I should have my plate done today.Bought 3 "make-your-own tstat gasket cards.I'll mark,cut,and drill everything today.Let me know if you still need one. If you have a good parts store there,,,the FelPro # is 71216 Last edited by '02HD#3982; 12-10-2007 at 11:50 AM. Reason: found p/n

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12-09-2007, 08:02 PM	#3 (permalink)
Krix330cic(NJ) _ HATERS WELCOME _ Paid Member Join Date: Feb 2003 Location: South Jersey Posts: 4,888 NHTOC member #: 290 View this user's gallery iTrader: 0 / 0%	Josh, can you make me a pattern on construction paper, and mail it to me? Im going to crank out a ton of these outta gasket material, and hook the guys up for free with them.

12-09-2007, 09:11 PM	#4 (permalink)
chupac Lovin' it Paid Member Join Date: Jun 2007 Location: Los Lunas, NM Posts: 726 NHTOC member #: 509 View this user's gallery iTrader: 0 / 0%	Very nice combo mod. I'll be doing this one when I do an oil separator. I did 1/4" holes on mine and have only had it stall once. That was after sitting outside in 30* weather all day and not getting a good warm-up before driving away.

12-10-2007, 06:17 AM	#7 (permalink)
Harley#356 Worlds Fastest HD F150!!! Paid Member Join Date: Jan 2003 Location: Week-Philly; Weekend-Souf Jerz Posts: 23,527 NHTOC member #: 3 View this user's gallery iTrader: 0 / 0%	krix I'll see what I can do. if somebody has their IAC off though with a gaskets thats still good, it'd be a little easier for them to go off that than me trying to go off the IAC and measure out the holes, etc. cuz I never got a gasket with mine to begin with

12-10-2007, 09:27 AM	#8 (permalink)
Krix330cic(NJ) _ HATERS WELCOME _ Paid Member Join Date: Feb 2003 Location: South Jersey Posts: 4,888 NHTOC member #: 290 View this user's gallery iTrader: 0 / 0%	Yea, id pull mine off and get crackin', but the trucks not in my garage.

12-10-2007, 01:18 PM	#11 (permalink)
'02HD#3982 Registered User Join Date: Nov 2003 Location: Ks Posts: 2,650 View this user's gallery iTrader: 0 / 0%	Used 11/32 holes for my '97,,,no stalling.Idle drops ALOT FASTER.Used to rap it up,,and it would stay around 1500 for a few seconds then creeeeep down.Now it just falls straight to idle.Me likey!!!!!

10-04-2008, 08:10 PM	#13 (permalink)
Krix330cic(NJ) _ HATERS WELCOME _ Paid Member Join Date: Feb 2003 Location: South Jersey Posts: 4,888 NHTOC member #: 290 View this user's gallery iTrader: 0 / 0%	Did it. Made out of aluminum, and went with the 3/8". Didnt notice much, but it was nice to work on the truck today, then take a ride down the Parkway.

10-04-2008, 09:32 PM	#14 (permalink)
'02HD#3982 Registered User Join Date: Nov 2003 Location: Ks Posts: 2,650 View this user's gallery iTrader: 0 / 0%	I just used the factory gasket on one side(stuck to the intake on both,the '97 and the 5.0 Cougar I have now),,and the FelPro on the other.

10-04-2008, 09:35 PM	#15 (permalink)
Krix330cic(NJ) _ HATERS WELCOME _ Paid Member Join Date: Feb 2003 Location: South Jersey Posts: 4,888 NHTOC member #: 290 View this user's gallery iTrader: 0 / 0%	Ah, that was my plan just after typing my other reply... but then I got my 3yr old involved, to let him try drilling the holes. Needless to say, it was a little oblong, lol. Had plenty of aluminum, so we just went from there. Worth the laughs / time spent fartin around with him.