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Unread 01-09-2012, 01:35 AM   #31
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The HS looks great! Glad you found a use for it!
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Unread 01-09-2012, 02:23 AM   #32
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Originally Posted by rluciano View Post
Oh I forgot to mention. I installed the flex fuel sensor on the return line right behind the passenger side front wheel. Sticking with the 83 lb. / hr. injectors for now, but as someone observed that can easily be changed later.
Congrats on your progress - your engine bay looks great!

As a reference point for your injectors, I'm hitting 96-98% duty cycle out my 100 lb/hr injectors at 1.5 Bar on my 2.5L with GT3076R and E85. I'm sure that you'll top out your injectors soon enough given the components in your build.

Good luck tuning!
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Unread 01-09-2012, 06:45 AM   #33
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Great work there.

I wouldn't bother with a 4" intake.
I too have a 4" compressor cover but I use a 4"->3" silicone reducer to fit 3" ducting ahead of the turbo.
I'm not sure the resulting restriction is significant enough to hinder performance.
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Unread 01-09-2012, 05:58 PM   #34
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Originally Posted by Thom View Post
Great work there.

I wouldn't bother with a 4" intake.
I too have a 4" compressor cover but I use a 4"->3" silicone reducer to fit 3" ducting ahead of the turbo.
I'm not sure the resulting restriction is significant enough to hinder performance.
If you accept George D's 800 cfm, I think the velocity of the air in a 4" pipe would be about 26 mph and going to 3" ramps you up to 46 mph. My math may be very wrong. I'm doing this in my head and on the iPhone. But the ratio is going to be 4 ^ 2 versus 3 ^ 2.
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Unread 01-09-2012, 06:01 PM   #35
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Originally Posted by Pauerman View Post
Congrats on your progress - your engine bay looks great!

As a reference point for your injectors, I'm hitting 96-98% duty cycle out my 100 lb/hr injectors at 1.5 Bar on my 2.5L with GT3076R and E85. I'm sure that you'll top out your injectors soon enough given the components in your build.

Good luck tuning!
Tuning is the most fun for me.

So what would you think, 160 lb / hr for a 3 liter on E85 at 1.5 bar boost?

And would the 044 pump be enough?

I think I start with pump gas, but even with only 2 stations in town E85 sounds tempting.
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Unread 01-09-2012, 06:06 PM   #36
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Originally Posted by DDP View Post
I wouldn't get too crazy with that flex fuel sensor. That's much more complicated than people realize to setup correctly.
Derek what aspect of setting up E85 is tricky? The sensor should be straight forward with the Link. I would think fuel could be a linear interpolation between two maps. The boost and timing may be tricky.

And thanks everyone for your positive comments.
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Unread 01-09-2012, 06:45 PM   #37
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Originally Posted by rluciano View Post
And would the 044 pump be enough?
Have you replaced the wiring to the pump? I believe I've read somewhere that the 044 requires heavier gauge wiring to achieve peak flow, but I very well could be wrong.
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Unread 01-10-2012, 08:46 AM   #38
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Have you replaced the wiring to the pump? I believe I've read somewhere that the 044 requires heavier gauge wiring to achieve peak flow, but I very well could be wrong.
Meh, that is easy, 8gauge power run to the rear, trigger a 30A relay using the stock wiring, power to the pump, pump to ground...

Beauty of the power wires I sent Rick is that adding the aditional power lead for the pump taps right into the terminal strip on the power side, or directly to a terminal on the kill switch.. isolated from the battery via a kill switch and without the switch in the on position the fuel pump will NEVER turn on!

Rick, let me know if you want a setup ready to install as described, as I believe I have everything on hand to accomplish it.. and can make it plug and play to the terminal strip! (I also have an 044 I will be using, although my batteries will be in the hatch area so my specific wiring will be a bit different!)
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Unread 01-10-2012, 10:29 AM   #39
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Quote:
Originally Posted by rluciano View Post
If you accept George D's 800 cfm, I think the velocity of the air in a 4" pipe would be about 26 mph and going to 3" ramps you up to 46 mph. My math may be very wrong. I'm doing this in my head and on the iPhone. But the ratio is going to be 4 ^ 2 versus 3 ^ 2.
We can reasonably expect that intake air velocity into the compressor inlet will never be high enough to create any pressure there, unless perhaps if the turbo doesn't spin at all and if there is forced induction ahead of the compressor inlet - unrealistic in normal running condition.

From there on, I understand that reducing intake air velocity to the compressor inlet equates to increasing the restriction in the compressor inlet and increasing the resulting (and normally expected) vacuum, thus increasing axial load on the turbo shaft. By which % I couldn't tell but whether a 4" or a 3" intake is used, I feel that the restriction of the air filter ahead will always have a more significant impact to intake air restriction than the diameter of the ducting to the compressor inlet.
Theoretically, the free-er the intake, the faster the turbo spool, but I doubt this could be quantified with anything but a PC log.

Or maybe I'm missing something?

Last edited by Thom; 01-10-2012 at 10:49 AM.
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Unread 01-10-2012, 07:13 PM   #40
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I would think that you're getting pretty close to needing a 2nd pump. I'm not sure what the tricky part in setting up the Fuel Flex sensor is. I'll try and find out from the guys putting it in my car if it's of any use.
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Unread 01-11-2012, 03:19 AM   #41
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Originally Posted by rluciano View Post
Tuning is the most fun for me.

So what would you think, 160 lb / hr for a 3 liter on E85 at 1.5 bar boost?

And would the 044 pump be enough?
If you are planning on running sequentially, I wouldn't hesitate using the 160's, but I think I'd have reservations about throttle response and driveability running those in batch fire / multi-point group. I didn't have any issues running the 100 lb-ers in batch with my 2.5L, but there was a substantial improvement in engine smoothness / crispness after switching to full sequential.

I've been running the walbro 392 pump for a few years now and it has kept up with the additional fuel flow needed for e85. I run 11.8-12.0 and so far my AFR is rock-solid reliable up to 1.5 bar and I can make it run richer if i needed to at this boost. As an alternative to the 044, it's been a good pump for my needs.
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Unread 01-11-2012, 04:34 PM   #42
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Default Intake accomplished (almost)

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As far as the intake is concerned, you're correct, no headlights on Waqqas' car. It's super tight in that area with headlights. The only other way I could say you could run a 4 incher is if you cut out that sheet metal and run a 90 down below the frame rail. I'm not sure if that'll work though.
Maybe I'm crazy, but there had to be a way to make it work. So water lines rerouted under the frame rail. And voila....
Click the image to open in full size.

Okay I need to trim the foot long silicone boot, but I need to leave at least 5" so that the intake can't touch the positive connection on the alternator.

And then a filter is needed.

Click the image to open in full size.

KN filter 4"flange opening , 9" X 5-3/4"Base, 7" X 4-1/2"Top, 4"High

I think this will be adequate.
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Unread 01-11-2012, 10:57 PM   #43
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Originally Posted by odb812 View Post
Have you replaced the wiring to the pump? I believe I've read somewhere that the 044 requires heavier gauge wiring to achieve peak flow, but I very well could be wrong.
Not yet, but it is on the list of things to do. Finally that list is getting shorter.



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Originally Posted by John Koa Wood View Post
Meh, that is easy, 8gauge power run to the rear, trigger a 30A relay using the stock wiring, power to the pump, pump to ground...

Beauty of the power wires I sent Rick is that adding the aditional power lead for the pump taps right into the terminal strip on the power side, or directly to a terminal on the kill switch.. isolated from the battery via a kill switch and without the switch in the on position the fuel pump will NEVER turn on!

Rick, let me know if you want a setup ready to install as described, as I believe I have everything on hand to accomplish it.. and can make it plug and play to the terminal strip! (I also have an 044 I will be using, although my batteries will be in the hatch area so my specific wiring will be a bit different!)
I just might be interested in that John. I'll PM you later. Also I hope you got the connector that I sent. I just used priority mail since it was so much cheaper than UPS or FedEx.

I have John's battery cables and cut-off switch in.
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Unread 01-12-2012, 11:05 AM   #44
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Originally Posted by rluciano View Post
I just might be interested in that John. I'll PM you later. Also I hope you got the connector that I sent. I just used priority mail since it was so much cheaper than UPS or FedEx.

I have John's battery cables and cut-off switch in.
I did receive it, thanks...

And no worries on the suplimental pump wiring... I have 1000 feet of 6 gauge, and probably close to 500 feet of 8 gauge primary wire on hand, along with all teh bells and whistles to set this up... I doubt I am going to have a run on the wire any time soon!

And just like the battery cables, I am sticking with the SGX cable... this stuff is proving to be quite versitile... and tough as nails!
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Unread 02-14-2012, 10:48 PM   #45
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Default You can have headlights and a 4" intake

Click the image to open in full size.

I told you it could be done. 50mm Hella projectors DOT approved and all.


A little finish work to go. But I like the light and a true 4" intake.

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