looks like youre on the right track bro. cant wait to see how it turns out.

 

So its time to continue this thread now when I have some more progress to talk about.

Above is a pic of me cutting my last year minfold apart to try to solve the boostcreep.
I had a 7psi spring and the boost did creep to something like 11-12psi at 8-9krpm. Simply too low capacity on my WG tube.

Unfortunately I dont have much or good pictures since my camera decided to die, but I did some shots with my phone at least.

After struggling to decide on if to rebuild the entire minifold or just change the WG, I landed on rebuilding the manifold and replacing the WG,
to avoid a solution that possibly werent enough. Below is an overview of how my new WG is mounted to my hotside. Had to build a new dumptube.
The placement of the WG is very narrow, both to engine and motormount. Took some time to get it right.



This is a shot more specificly on the manifold after I did improve the flow route for WG gases. Note the bend going into the dumptube.
The difference inside the manifold is significant and the picture doesnt really give it justice.



So did it work? Yes it did, with a 6psi spring in my new WG, I am holding 6psi all the way to the redline. Rock solid WG capacity.
The next step is to activate my EBC solenoid and up the boost to maybe 10psi from spool to redline. Should result in close to 400whp.
Car runs strong already at 6psi with this setup.

 

Now that the car is driveable again, I can spend my free time on other stuff like catching 14ib pikes for example. This lady was released right after the photo.

 

great fish and fantastic news about the manifold bro!! now all you have to do is up the boost and make another manifold for me!!! lol. great job bro let me know how it turns out k.

 

Time for a small update.

The current situation is that all the new silicone hoses for the WG and EBC are installed and the car is ready for more boost.
However, to be safe I bought a Bosch 044 fuelpump. This one does not fit in the stock hanger ofcourse, so right now I am building a new hanger.

I made a separate thread about some questions related to the hanger as I had a memory of that the hangertop having a complicated shape.
However that was not the case, only the rubber sealing has the weird shape.
(I did never separate those parts when I changed my pump to the walbro.)
So then it was easy to start with the fabrication.

This is how the Bosch 044 looks with a stock hanger thats equipped with a walbro 255. Obviously too big.
Notice the waist on the pumps outer shell. That waist is resting ontop of the support later on.


Started off with making a 3mm stainless disc. Same thickness as the stock plastic.
Diameter is 108mm for anyone interested in that.


Welded a ring to support the sealing just as on the stock hanger.
Supportring outer diameter is 95mm.



Fits nicely.


Made a holder for the fuel level sensor. Same placement as stock.


Added support for the fuelpump.


Just testing it together, looks promising. I am going to place the filter on the same height as stock.


So next week I will get some fittings and fabricate the last parts and then I can throw it into the tank. Should be a sweet to never again worry about a walbro that COULD break from E85.

 

im am humble in your existance lol. you have some mad skills bro. i need to start welding so i can start doing my projects that i have in mind lol. i just recently picked up a 1976 datsun 280Z for a resto mod kind of build. welding is a must so im going to learn on that. love your fab work and im prolly going to borrow from you when it comes time to redo the fuel system.

 

I am currently struggling abit to decide on sealings for the cables to the fuelpump and fuel level sensor. Got the pumpcable sealings sorted, but still not happy with the weaker fuel level sensor cables. Got a picture of the part that will allow me to connect my hanger to the stock feedlines.

I will weld this one to the feedpipe that comes from the hanger.

 

That should work great, pass the wires through and fill it with epoxy and call it a day.

 

From what I have tried, (2 different quality epoxy glues) they seem to wear out over time from the E85 fumes. The hardened glue gets softer and brittle. Therefor I am taking another approach. Something more solid.

 

Okay, time for an update.

Today I took the stock insert out again (have been driving the car the past few days) and went for the final push in the bosch 044 project.

Started off with checking that my homemade connection did fit the oem plastic locking device.


Made several holes in the hanger for all stuff going through it. At this point still experimenting with possible sealings for the thinner fuel level sensor cables.


Then I got this nice idea and took some silicone hoose and put it into a copper tube and pressed it into a washer. Washer simulating the hangertop. Looked good enough to go in that direction.


Went on and fabricated the connection for the pumpfilter. It is simply a piece of stainless tube welded onto a cut off fitting.


The filter is pressed onto the tube with quite some force. It will not get anywhere.
An o-ring is sealing between the pump and the fitting.


Installed the sealings for the cables and the fuel return connection.


Extra tight seals for the pump cables.


The hanger is ready for action!


When I started the car I had to decrease the fuelpressure on the FPR. this pump did reach 5bars at the setting where the walbro managed 4,2bar. Obviously flowing abit more.
The drive home from the garage was pleasant and the pump seems to be doing great. I can hear it under quiet circumstances but some extra sound isolation will fix that. I am now satisfied with my fuel setup.