I know - and that's a big reason I have the meter - but finding out on the meter that the system is inadequate means I provided p*ss-poor planning. <img src="/forums/images/graemlins/wink.gif" alt="" /> If it won't stay green under boost, you can bet yer <img src="/forums/images/graemlins/butwiggle.gif" alt="" /> the pump will be changed to a Pierburg unit.

Frank

Fuel injectors have been a holdup.... I won't relate the whole saga and name names (to protect the guilty), but it's been kinda aggravating dealing with this issue - partly my own fault for not having sent them for flow testing sooner.

The 6 INP-053 (B240H) injectors were supposed to be matched. When they arrived without paperwork on flow data, I was suspicious and should have sent them off straight away for testing, but kept putting it off. Finally, I sent them to CruzinPerformance for flow testing and Rich found a 5.7% difference from high to low <img src="/forums/images/graemlins/scared.gif" alt="" />....... not good enough by a long shot for me. After I "talked" with the original supplier, he had 6 more cores sent from another supplier to Rich... I had Rich clean everything and test all 12 injectors at 3Bar and 4Bar. He tested at 43.5 and 58 psi. I got lucky and the pile of mess turned into gold. <img src="/forums/images/graemlins/smile.gif" alt="" />

From the 12 injectors, I put together a set of 6 that are matched better than any I've seen:


The six in front are the closest and flow tested as follows - ratings in lbs/hr @ 43.5/58.0 psi:
#1 - 23.86/27.71
#2 - 23.86/27.71
#3 - 23.86/27.71
#4 - 23.86/27.71
#5 - 23.86/27.97
#6 - 23.86/27.71

Outstanding! <img src="/forums/images/graemlins/kewl.gif" alt="" /> They're now installed:


Frank

Nice. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Prepped the intake flange, blower plenum flange and both sides of the MLS gasket with 2 coats of Copper Spray-a-Gasket and used a couple of headless bolts for guide studs to install the plenum:

Installed with allen socket screws/knurls removed by grinding:

Hand cut paper gaskets for the plenum/blower plate and blower inlet flange.... the top gasket will be trimmed again to fit the blower flange:

Hooked up the fuel lines to the regulator and the wiring for the in-cab fuel pressure gauge sender:

Drilled/tapped a hole on the coil bracket and installed the ignition circuit choke and capacitor:


Now waiting for the new blower to arrive.... again. <img src="/forums/images/graemlins/rolleyes.gif" alt="" />

Frank

It sure took a while, but I finally have a blower made to the correct specs <img src="/forums/images/graemlins/kewl.gif" alt="" />:

Mounted on the blower plate, along with hose clamps to secure the IAC heater hoses:

Test fit for nose drive length/drive belt alignment - looks perfect <img src="/forums/images/graemlins/smile.gif" alt="" />:



I'll get back to work on it again in a couple of days when I have some time. <img src="/forums/images/graemlins/sleeping.gif" alt="" />

Frank

That looks great!!

Oh crap I am going to get stuff allover my hands and keyboard. That usually only happens when looking at other types of pics. <img src="/forums/images/graemlins/smile.gif" alt="" />
<img src="/forums/images/graemlins/kewl.gif" alt="" /> good job.

Is that it for mechanical alignment? In any case, congrats. That was the really tough part done, and done nice...

Not quite, but it's the worst of it - and the part I spent a lot of time on with the mockup so it would hopefully come out right and not waste expensive aluminum and machine time.

I've now final mounted the blower and inlet pipe and find the two supports (fore and aft) are very slightly misaligned - nothing serious. In this photo you can see the rear support brace hole needs about 6 strokes with a rat-tail file to get the bolt in:

The nose brace shown in this photo will screw/clamp onto the nose, butt to the machine cut and then be secured by a screw through the front of the brace into the alternater serpentine belt shroud hole and another yet-to-be welded brace tab on the upper rear of the brace to the top hole on the alternator saddle mount. The brace will also be through-drilled for the idler bolt:

Here you can see that it appears I missed the measurement on the nose milling by approximately .015" <img src="/forums/images/graemlins/wink.gif" alt="" /> so either I have to mill the rear of the brace... or give the alternator saddle boss about 3 strokes with a flat file <img src="/forums/images/graemlins/lol.gif" alt="" />:

Actually, everything is so dang close I probably could have hit the blower with a rubber hammer before I tightened everything down and all would have been perfectly aligned. <img src="/forums/images/graemlins/kewl.gif" alt="" />
Here you can see the IAC hoses routed from the rear pipes through the hose clamps... I'll cover those with some split loom to avoid chafe on the blower plenum edges:

I need to adjust the CCV hose angle a little better to get it to nestle between the IAC heater hoses before I zip-tie it to all together. Here you can see the hoses coming around the other side of the blower to be installed to the IAC and inlet air duct:


Tomorrow I hope to find time to lengthen the various wiring harnesses... and I still have to shorten the throttle and kickdown cables, change the IAC hose fittings and construct an inlet air duct before I can try to start it. It sure shouldn't be as long as it's been, though.

Frank

6 strokes? 3 strokes?
Fargin' Fantabulous, Frank !!!!!!!!

Ed