So have shifted back to working on the engine again. I hadn't quite finished off the inlet manifold so I spent a few hours with the dremel cleaning up the welds around the injector ports inside the runners.
Shaped them all with the carbide bit so they looked like the above then swapped the bit to a sanding drum and tidied them up. Also welded a plate onto the underside and drill and tapped the NPT hose fittings for the brake booster and vac line take offs.
Then finalised the mounting of the idle speed controller. This is a two wire PWM bosch unit and will be controlled via the link to handle cold start idle up and load rpm adjustments (for headlight/alternator load etc) along with being the air bypass for antilag.
I ran a similar setup on the old engine via the old Linkplus but with the G4+ the control is quite alot nicer. I wont have any of the issues of un-even idle or difficult starting that I'd seen with quite a few customers cars that have come thru. Should be able to adjust idle quite accurately and also have progressive warm up idle speed adjustment like factory.
Here's a photo of the old setup - will retain the same bypass piping to the intercooler pipe.
I was never very happy with using a stock 4age fuel rail as it had an extra mount that I wasn't going to use and the top mount reg and feed which I was going to have to fill and machine back.
So, I bought some Aeroflow fuel rail extrusion and started to make my own fuel rail. I was thinking about centre feeding this with returns from both ends hooking down to the fuel pressure reg that I would mount under the inlet somewhere but in the end I decided this was overkill and end feeding was fine.
Stock rail
Aeroflow extrusion
Chopped then rail to length, then used the milling machine to drill holes for the M5 mounting bolts. Then used a 10mm milling bit to recess the cap screws into the rail so the heads sit flush - trying to make it look tidy.
Reamed the ends to allow the aeroflow -6 weld on fitting to slide inside the rail
Then welded them on
So it looks like this
Copied across and drilled the injector ports
Sat it all in place and measured up the spacers needed to bolt the rail to the inlet (already had tabs between the runners from fitting the stock rail). You can see the throttle cable bracket welded under the plenum, you can hardly see the cable so its quite tidy. Still need to trim the length of the idle speed controllers bypass hose.
You can see the idle speed controller under the inlet
Chopped the fuel rail spacers then drilled/tapped each end and fitted them. The rail is rock solid - fingers crossed there are no leaks. I've started buying the fuel rail fittings but need to mount the fuel pressure reg before finalizing the final fittings and pipe I need. Will be using stock piping from the 044 pump to the fuel filter on the fire wall, then -6 fittings and line from there to the rail > reg > return. If I looks like the stock fuel line will be a restriction then I'll change it but I'm hoping to get away with it.
So this is where its at now. Next is mount the fuel reg, fit the fuel pressure sensor for the Link, and make up the lines - then the fueling side is all done.
I've started to design the mount for the HEC715 coils, just need to decided on the final spot (somewhere over the gearbox probably) and the Link ignitor mounting location. Will mount the coils like this probably.
