SHELBY GT 350 Member
Joined: Sep 2010
Location: see user name
If you absolutely cannot bring yourself to buy another PI intake, your best option is to look on Ebay for an '01 Bullitt intake. They are pricey - I usually see them for around $500+, but they are made from cast aluminum, fit perfect because they are an oem part, and you will get decent gains throughout the rpm range (probably about +15 hp peak). This is one part I really wish Ford would reproduce.
Another option that looks interesting, but I haven't heard much about, is the Trick Flow 'Street Heat' manifold. From the outside it looks almost identical to the Bullitt manifold, I'm not sure how it performs though so you'll need to look into that. Fitment and overall quality should be good with anything Trick Flow.
Yet another option is Edelbrock Vic Jr. manifold.... Fitment is good and install pretty straightforward, but pretty sure it's a little nore involved than just a manifold swap - IIRC, the stock fuel rails are not compatible with it.
As far as performance, unless you have heads and cams (at a minimum) to realize the additional airflow, you're not going to beat the stock PI or Bullitt intake though. At least in terms of discussing the Typhoon or Vic Jr. intakes, like I said I'm not positive how the Street Heat compares to the stocker. There's a reason that pretty much only people with built engines have aftermarket manifolds. And even then, the composite PI is still good to about 500 hp.
And I wasn't aware of all the various issues you mentioned about the Typhoon - all I'd heard was the casting was a little sloppy and as a result the ports needed to be cleaned up prior to install. Can't say I'm surprised though, as it is not known to be a well engineered piece.
2001 GT Convertible
All the usual bolt-on's /200 I6, C4
And a few Explorers too... 2008 4.0 XLT 4x2, 1996 XLT 5.0 4x2, 2003 Sport Trac XLT 4.0 4x4