After doing a lot of reading before starting the install of T242, I was in agreement with the consensus that relocating the knock sensor to the back of the head was not the best idea picking up cam vibes, etc. I also did not want the sensor disabled in the tune.
After doing the disassembly I was staring at the valley thinking when it occurred to me that the best location for the sensor was where Ford designed it to be. There was plenty of room under the lower intake. Here is what I came up with:
Tools Required:
The install manual wants you to remove 3/16" of the sensor mount bosses. I found standing in the engine bay the easiest way to complete this task:
Using a pencil & depth guage mark a line around the bosses at the required 3/16". Then using an air cut off wheel with 1/16 cutting wheel, slice the required piece of the boss off just like a meat slicer:
Before
After
You will now have 2 slices of the boss, use 1 as a template to mark the curve of the boss on a 1/2" aluminum spacer. I used an old alternator spacer in my bucket of junk parts:
Using a 90* air drill (air works best, electric is too large for the work area) drill a hole at 90* to the OEM bolt hole for the sensor (you will need shorty bits for this). You want the center of the hole you are drilling to intersect the bottom plane of the OEM hole, this will put the sensor just below the lower intake. The passenger side sensor I located slightly to the back of the boss as the casting was in the way if centered and this also located the sensor away from the rib on the bottom of the lower intake. Tap your new hole (M8x1.25 I think it was) to reuse the OEM bolt. Mix some JB Weld and coat the side of the boss and the curved side of your customized spacer. Slide OEM bolt thru the sensor, thru the spacer and in to your new bolt hole & tighten down. Now use some of the JB Weld to fill in the joint between the spacer & boss. Put a skim coat of antiseize on the bolt where it passes thru the spacer to prevent the JB weld from adhering to it, use blue Loctite on threads where the bolt threads in to the boss.
Here is the final result:
I think this would work for the engines with dual sensors if you use a low profile head bolt and do some manipulating of the coolant tube curve in the valley.
Worked great, runs great!