Big turbo build- take two

[DougLoBue]

between Vortex, QW, dodge forum, buell forum, and suzuki quad forum I don't get very much work done. don't know what i am gonna do when this student position ends and i get a real job

Network Administrator = I sit behind a computer and frequently go completely insane.

Network administrator for a large scale machine shop = I sit behind a computer, bull**** in the shop and get parts welded/machined for my car.

[speed51133!]

conventional efi has the regulator AFTER the rail. You can have it as far downstream of the rail as you want. The pump builds pressure and the regulator bleeds it after you hit a certain pressure. That is how the stock one works and aeromotive and almost all aftermarket regs.

Putting it BEFORE the rail would mean your injectors are not seeing hardly any pressure at all and your car would run TERRIBLE if at all.......

[DougLoBue]

Putting it BEFORE the rail would mean your injectors are not seeing hardly any pressure at all and your car would run TERRIBLE if at all.......

My car runs as it sits now ? I've probably put over 2k on it like this...

Seems to me like it builds pressure in the rail and bleeds off excess fuel when that pressure is reached, but opinions are welcomed- that's why I was asking!

[DougLoBue]

Well... Fuel pump and paint supplies didn't come in. Did get my MAF in and the housing isn't 4" but I did get it to run okay in my 4" intake pipe. Can't do any tuning due to lack of fuel pump...sucks

Funny that companies couldn't get my parts to me but ManofManyGTs from this forum got my 70mm TB out to me- thanks!

Did get a light cost of primer on the bumper after doing a lot of sanding and filling- just to see where we were at.

[01ttgt28]

Nice to see some pics sucks that you have had so many problems and you came back with a new build and your still having problems good luck

[PLAYED TT]

Looks good Doug. Cant wait to see it Saturday

[DougLoBue]

so a real integral part of my car making it to the GTG got in finally! I just need to get some -10an 90' turns and -10 an to -10 straight cut o-ring & a -6an 90' and this will be all done.

Next up is coolant relocation or delete. I don't like the idea of delete and I'm pretty sure the coolant ball has to be at the highest part in the system to work properly. My only real choice is to have a custom tank made that is going to be half the size of the old one or less or to delete. Opinions?

FUEL PUMP!



Modified the brackets a little



Grew a set of balls, drilled a couple of holes in the car and here we have it:

The -6 AN 90' pictured below will not be staying the pump will have -10 AN 90's on either side if I can find the right fittings to increase flow around the turn, that and all ports are -10an at this point.

[01ttgt28]

Do you really have to mount the pump in the engine bay???
Can't you run it under the car before the filter??

[DougLoBue]

Do you really have to mount the pump in the engine bay???
Can't you run it under the car before the filter??

No space down there, this is a pretty big pump. Also I think you need a filter before the pump to keep it in good working order.

Also I was told by Marcus to think of my fuel filter as a surge tank- which makes me feel much better because the damn thing holds 1/2 liter of fluid!

[01ttgt28]

No space down there, this is a pretty big pump. Also I think you need a filter before the pump to keep it in good working order.

Also I was told by Marcus to think of my fuel filter as a surge tank- which makes me feel much better because the damn thing holds 1/2 liter of fluid!

I found some thing for your coolant delete just needs a little welding and a cap should hold plenty fluid

[DougLoBue]

That would be sick!

I saw a mk2 or 3 build using the strut bar as an overfill- very clean!

I just put together a summit cart of AN fittings and custom coolant expansion tank weld on fittings and a 25psi Moroso radiator cap w/ overflow port. I'm going to try and have Ed @ FFE weld me up a mini custom expansion tank right between the fuel pump and the power steering resivour. Maybe I should ask if he can make a custom P/S too ? Make that whole side of the bay look a lot better...

[l88m22vette]

Why no in-tank Doug?

[DougLoBue]

Why no in-tank Doug?

Well the only E85 compatible intake solution I could find was still in development from Walbro and would only be 400 lph. I was told it might be released sometime in April. My other reason for keeping it in-line is just so I don't have to worry about driving around with less than 1/4 tank. Since my gas gauge doesn't work to begin with and I go through gas faster than the Valdez into Alaska that could have been a bad combo.

Another new part- 70mm throttle body, thanks ManOfManyGTs - great deal, quick shipping too!

I had two adapter plates that came with my aftermarket manifold- well neither of them worked for the throttle body. Time to cut, grind, drill & tap in that case. A t bolt & 3" to 2.5" coupler finished it all off.

Also tonight cleaned up some wires and that's about it. Hope my Summit stuff shipped out

Stock 60mm right, 70mm left

[PLAYED TT]

Wow you weren't kidding when you said it worked out perfectly! Good work man

[DougLoBue]

First page edited with complete mod list

Just re-pinned a bunch of busted connectors last night.

Oh and cut a huge hole in the trunk of my car. You guys know that hump in the middle of the spare tire. Yea I don't have that there anymore. I didn't take photos of the finished product, but 16gauge steel, 3M 5200 Marine sealant, rivets, sound deadening and rubberized under-body coating make the trunk flat now. All ready for a fiberglass sub box.

Muffler went flat black last week for less bling effect.

Rear bumper shaving coming up also- supplies purchased!

[PLAYED TT]

Good deal. Can't wait to see the rear

[Marcus_Aurelius]

Never a good idea to cut a unibody! I did the exact same thing in the silver EVO for weight reduction and allowing me to store race tires in the trunk. Well after perfectly welding the hole shut, the rear flex was so unbearable in the back (wobbly when cornering at the track) I had to reinforce the crap out of it, negating any weight saving and the possibility of carrying tires.

[DougLoBue]

Well the metal was very very thin and the hole isn't that large. My goal here isn't for weight savings, but to sink a subwoofer box in there - you know that one I have flying around the back of my car when we go tuning

I wouldn't mind re-inforcing it if I have to - or maybe this calls for a half cage install

[Audiguy84]

Looka good man, wish i came out to see this in person when i lived in nj.

[Forty-six and 2]

What did the 70mm tb come off of? You build its coming together nicely.

[DougLoBue]

Thanks & not sure- the last one I had was off a Mercedes.

[PLAYED TT]

Thanks & not sure- the last one I had was off a Mercedes.

Not sure what it's even off of?

[DougLoBue]

Custom coolant resivour with expansion cap/port and both OEM hookup lines was made by Ed @ FFE.

Also project Michael Jackson has begun. Introductory stages are rough. It's plastidip folks and just for fun- nothing permanent here. We did it in the cold so it kind of came out rough like sandpaper & we really need another gallon or two of the stuff because you can really see the black in a lot of places. I'll get a thread up with more pics outline the process - Greg did this for me on a Thursday night in a couple of hours for under $200.

Did a TTRS cruise/gtg this weekend- met James down there and he got some good rollers of the car. Put about 600 miles of non-stop beating on it this weekend- it was glorious.

[01ttgt28]

Wow you did the whole car?was it hard?
Played put up some pics didn't even know it was your car
Till i Seen your engine bay looking good

[Audiguy84]

Still running that red hose i see.

[DougLoBue]

Wow you did the whole car?was it hard?
Played put up some pics didn't even know it was your car
Till i Seen your engine bay looking good

It wasn't hard but we did a terrible job due to the cold or us being inexperienced. I'm currently debating re-doing it or just doing another gallon on top to make it whiter for the time being.

Still running that red hose i see.

I'm not sure if you're aware but the red hose adds an additional 5' Celsius of cooling per inch of red used. The formula is outlined somewhere in this document:

http://arxiv.org/pdf/1204.0162v1.pdf

aka I've been too lazy to just order a few feet of the black coolant hose from Vibrant

[DougLoBue]

I've been afraid to run this due to plastic, large turbo close by and heat but it's been sitting on my shelf so why not and I keep a fire extinguisher in the car anyway. When I cut the two pieces off to fit I found out that the plastic is really thick- my Dremel had to really work even with a plastic cutting disc to get through it.

[PLAYED TT]

That fits really good. I'm glad you kept it.

[jbrehm]

Project Michael Jackson

The coolant reservoir looks perfect, especially with that fuel pump location! What type of fuel hose is that? Is it just clamped onto the stock fittings before the fuel pump there?

I'd definitely get a turbo blanket, though - my top mount runs hot as f*ck in Summer, even with a turbo blanket and wrapped DP.

[DougLoBue]

Fragola braided black -6 AN - yep just clamped to the stock fuel line location and works great. All other fittings are proper reusable AN fittings.

[01ttgt28]

Def get a Turbo blanket looking good hows she running

[20v master]

I've been afraid to run this

Have a part number or know what it is off of?

[DougLoBue]

Have a part number or know what it is off of?

OEM connector cover off the MK5/6 part number is: 06F 971 824 C

http://www.ecstuning.com/Search/06F_971_824_C/ES281285/

Dealers have them for the same price too- that's where I got mine.

[DougLoBue]

Okay... somebody here please tell me I'm an as*hole:

My car has positive corrections under full boost as seen a few pages back. Increase the boost, corrections increase and the car goes super lean. Initial thought was not enough fuel. I was wrong.

With a MAF hooked up at 20psi I'm pulling 313 grams/sec @ 6800 rpms! Way outside of a regular K04 that the ECU accounts for (IIRC) a max of 220g/sec. I could only imagine what a 30psi pull does...

I can't get the car to idle with the MAF though- plug it in and it stalls out. Well this is where I'm an even bigger idiot. I have a BOV that at idle & driving in vacuum is letting in un-metered air- under boost it's letting out un-metered air.

$400 fuel pump, $100 in fittings, custom coolant res. & a REALLY loud pump for no reason.

So solution: I'm going to need to have my TIAL BOV port cut off and a pipe welded in it's place. Need two bungs welded on- hot side pipe & intake pipe are luckily right next to each other on the drivers side of the motor. Going to need a MadMax valve I think... the real question becomes- can I get this all done by Friday so I can make real boost (over 30psi) for the dyno day? Probably not.

[20v master]

Again, all reasons why I prefer MAFless tunes. And can't you put a stiffer spring in the TIAL BOV so it's closed at idle? Another reason I prefer my adjustable Greddy Type S BOV. Either way, you'll need the fueling capability once you start upping the boost on the E85.