The upper intake manifold started life as a piece of a 1987 EFI Truck upper intake.

 Next, a lower plenum was fabricated and welded to the piece of casting.
This plenum will support the charge cooler

 The upper manifold then made a trip back to the mill to square up the sealing surfaces
as well as the top of the manifold where the cooler will be welded to.

Prior to welding the cooler to the lower piece, a couple of minutes were spent with a carbide cutter
and sanding roll to knock the sharp edges off of the port entrances.

Here is a few pictures of the comparison of intake port size between my  modified 1987 truck upper intake
and a stock 1988 5.0 mustang intake. At this point the cooler has been welded to the intake and now the cooler inlet will be fabricated and welded on..
The cooler is actually an air to air unit that I will be using in an air to water configuration, hopefully it will be capable of providing
a reasonable temp drop across it.
 

Unfortunately I did not flow the lower section of the manifold before it was installed on the engine, but I feel it will be adequate for my
current engine configuration. As for the operating range of the manifold from a dynamics point of view, I would expect it to be a good high
speed manifold for a naturally aspirated car (minus the cooler of course). If I get a chance to do some rough calculations on the
operating points of this manifold I will post them here in the future, but right now it is not too big of a concern for me (nor should it be in a
forced induction motor). I'm pretty confident that I'll be able to fill the cylinders quite well regardless of the manifold dynamics :).

On the left side is the front view of the almost finished upper intake manifold, on the right is the rear view. The reason I say almost finished is that I still have some cosmetic work to finish on it. A big THANKS!!! goes out to Jim for a good portion of the welding done to this manifold, it's kinda easy to see where I welded and where Jim did, the crude looking stuff is mine. As for finishing the manifold, some of it will be polished, some painted, and possibly some laser etching may be added to the top. It is currently in a full functional state now though.

Here are the left and right views respectively, on the left view you can see the water connections to supply the cooling to the charge cooler. I did toss it on the flow bench but all I could test was the flow into each inlet individually mainly looking to see the distribution out of the upper from port to port. The distribution looked very good and flowing only one inlet, it managed to moved 417 CFM @ 8" H2O (0.289 psi), this is basically the limit if the 3" inlet pipe. It is probably safe to say the upper manifold  is capable of 1000 CFM flowing both inlets at 0.5 psi pressure drop (14" H2O). The next test I did was to run the flow bench until the discharge reached an output temperature of 105F. I then filled the cooler with tap water (~ 60F) and quickly but it back on the bench. When I fired the flow bench back up I was treated to a nice cool discharge from the manifold for about 5 - 10 seconds before it started to feel warm again. At this point I pulled it from the bench and drained the water from it which now felt close to 90F. I know on thing for sure now, it's going to melt alot of ice in a 1/4 mile pass!!!

Here is a shot of the manifold the engine gets to look at. Next step, make it look good!