Lebowski
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| posted on 22/3/12 at 02:21 AM |
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Looks like a nice job
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Glade
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| posted on 29/3/12 at 03:24 PM |
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Started fitting pipes last weekend. I have realised that with the new spacing the existing spacers in the fuel rail ONLY JUST fit, and it's a
bit dodgy.
So I have knocked up a design for replacements, extended to fit snugly.
Also created a connector block and some shorter sections to join to the high pressure fuel line. I've sent it out to a local machine shop but I
think that it'll cost a lot to get made...
ETA: Getting a machine shop local to me to do them... £75 - doing them tonight or tomorrow - should be able to pick up Sunday!
[Edited on 30/3/12 by Glade]
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Glade
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| posted on 30/3/12 at 05:57 PM |
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Within 24 hours these have been produced!
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tasmod
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| posted on 3/4/12 at 01:30 PM |
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Curious as to why you went to the trouble of making up the fuel rail and used the smaller GSXR injectors when the 4age has a very good setup with its
own seperate fuel rail with correct injectors.
[Edited on 3-4-12 by tasmod]
Rob
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Glade
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| posted on 3/4/12 at 01:41 PM |
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I didn't have any original 4AGE parts.
The car had dellorto carbs, and a custom manifold when I got it.
I didn't consider sourcing the original manifold & injectors!! Isn't it a big curly thing??
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tasmod
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| posted on 3/4/12 at 01:45 PM |
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No, the injector rail is separate and bolts with spacers to the holes in the head top (side) if you get what i mean.
Rob
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tasmod
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| posted on 3/4/12 at 01:57 PM |
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You have U2U
Rob
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Andybarbet
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| posted on 3/4/12 at 08:42 PM |
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This is a great thread, im doing a similar thing on a zetec engine, same throttle bodies & modular fuel rail but I picked up an ali plate with 4
pipes on it type of inlet manifold.
Your fuel rail extensions are looking good :-)
Im planning on turning mine from some scrap brass rod ive found at work, did you keep the hole through the spacers the same diameter as the original
ali ones ? or is it preferable to have a larger bore for the fuel to flow through them ?
If it works ok, im going to mill a flat on the outer 2 so that i can drill then tap into it, this way i should be able to screw in a brass hose
connector for flow & return. I will post a picture when ive tried it.
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Glade
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| posted on 3/4/12 at 08:55 PM |
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I made them the same bore as the originals.
The connector block also has approximately the same gap within it where the pipes meet.
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Andybarbet
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| posted on 3/4/12 at 09:01 PM |
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I shall follow your lead then, atleast having the same bore as the original, it leaves me more 'meat' to mill a flat on & drill/tap
into it.
Cheers 
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HowardB
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| posted on 3/4/12 at 09:12 PM |
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I made new fuel rail elements exactly the same, but now I don't need the throttle bodies or the st170 inlet manifold,.. all part of the joys of
the evolving kit
Howard
Fisher Fury was 2000 Zetec - now a 1600 (it Lives again and goes zoom)
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AntonUK
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| posted on 3/4/12 at 09:34 PM |
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Could I ask where you got your swirl pot and HP pump?
Build Photos Here
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Glade
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| posted on 4/4/12 at 07:17 AM |
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Ebay... £50 each.
There are some swirl pots there for £30 which look reasonable.
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Glade
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| posted on 10/4/12 at 09:17 PM |
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It started first time!
Tonight I mounted the swirl pot, pressure regulator & plumbed it all in.
Did a little wiring, created a clear path (to roll a burning inferno away from the house into my neighbour's garden), and went for it.
Cranked for about 20 secs, and it fired and settled into a reasonable idle!
Wahoooooo! Can't wait to let it run for a bit tomorrow!
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MakeEverything
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| posted on 10/4/12 at 11:42 PM |
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quote:
Originally posted by Glade
Tonight I mounted the swirl pot, pressure regulator & plumbed it all in.
Did a little wiring, created a clear path (to roll a burning inferno away from the house into my neighbour's garden), and went for it.
Cranked for about 20 secs, and it fired and settled into a reasonable idle!
Wahoooooo! Can't wait to let it run for a bit tomorrow!
Great Thread. A word of warning though;
I bought one of those Pressure regulators, and it was causing massive lean spikes in the early stages of tuning (static low revs). It took me ages to
realise it, but for some reason, the diaphragm isnt consistent and seems to flex randomly. I had the injectors cleaned, checked the throttle, fuel
hoses, pump, filters and everything but. Eventually, i looked at my shiny new regulator and took it to bits. The internal quality is alarming, when
you think of the consequences of it not working properly.
I took it off in the end and went back to the little OE item which works fine. I'm yet to be convinced i need to spend another £80+ on a proper
FPR, as the OE one works so well.
Kindest Regards,
Richard.
...You can make it foolProof, but youll never make it Idiot Proof!...
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Glade
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| posted on 11/4/12 at 06:27 AM |
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I did wonder about it being so cheap!
Can anyone reccomend a suitable replacement??
How about this...
http://www.merlinmotorsport.co.uk/p1850/FUEL-PRESSURE-REGULATOR-8MM-+-GAUGE-PORT/product_info.html
[Edited on 11/4/12 by Glade]
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Oddified
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| posted on 11/4/12 at 08:25 AM |
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I also bought one of those cheap regulators, but i took it in bit's before fitting to have a look inside....rubbish. It never went on the car
and it's that bad i decided not to off load it on ebay either
Took the pipe fittings off and threw it in the bin...
Ian
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Glade
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| posted on 1/7/12 at 09:48 AM |
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Just thought I'd update this...
Bought a better fuel regulator, car is running now. Just needs a remap - which is on hold due to lots of other stuff going on.
Doesn't look like the car is going to see the road this summer 
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fsmlittler
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| posted on 23/7/12 at 09:27 PM |
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What fixings did you use for the throttle bodies to the adapter plates? There is very little space on the TBs for the bolts or did you tap the plates
and use studs?
Also Ive got hold of the Jenvey modular fuel rail but it's designed for 14mm 'O' rings and the GSXRs are only 10mm-Jenvey say you
can just put bigger 'O' rings onto the injectors-has anyone else done this?
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Glade
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| posted on 24/7/12 at 11:14 AM |
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I tapped holes and used one cap head screw on each TB.
The TB casting has something in the way of the right hand hole, and without some rework you can't get a screw in.
The interference fit with the bracket, the sealant and the single screw make it very solid though.
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