JP3 that is one heck of a job on one heck of a project.

 

It's the same intake. I considered many options for attaching the bungs and finally decided to tap them for set screws. The last intake I converted to efi (for the original BBR truck) had JBWelded bungs and it worked ok, but I was always concerned that they might come loose and cause a vacuum leak. The set screws create a mechanical connection and will allow me to have them welded or use JBWeld to stabilize and to basically just seal them up. The set screws I purchased were too long. Final screws will be shorter and the bung protrusion will be mostly trimmed away inside the port.

 

Very neat. Thanks for clarifying. Excellent progress so far, looking forward to the final results.

 

Are you going to grind down the parts of the bungs which protrude down into the ports? It looks like they would shroud the injectors' spray patterns.

 

Yes, That will be the last thing I do to them. Carbide cutter in the air grinder will make short work of them.

 

Some shiny parts arrived on Friday. 20 gallon fuel cell (because I didn't want to deal with the old tank anymore) and a 31x13x3 intercooler.

 

Being the DIY guy I am, I went ahead and used JBWeld to seal up the bungs. I mixed it up, pulled out a bung, coated the bottom portion, slid it back in, twisted and wiggled it, then installed the set screw. Might have got a little much on them, but I'd rather it be too thick than too thin. Besides, I'm not out to win any beauty contests with this thing. When I checked on them this morning, it seems as if they are solidly fixed and sealed. I feel much better about these than the one's I did for the original Ranger big block project.



Next phase is to drill the injector feed holes in the blank fuel rails.

 

Drilled the fuel rails. They turned out ok.

 

Out of curiosity, how are you planning on holding the rails & injectors down to the manifold? Just curious, because this looks pretty good! I used JBWeld to secure the turbo oil return fittings to the oil pan in my old Mustang. My dad had the idea of using the heat gun to "flow" the JBWeld, though they have to be done one at a time that way. Gently heating up the epoxy will cause it to loosen up & flow evenly (or it can run - be careful!) around the bung/fitting.

 

On the last one I did, I made simple brackets that attached the fuel rail to the intake manifold bolts that are between cyls 1-2, 3-4, 5-6, 7-8. I woll probably do something similar this time.

 

Took a few minutes today to start trimming the bungs in the ports. One side is trimmed. The air grinder and carbide cutter make fairly quick work of it. A sand roll in the Dremel will be used to finish it up.

 

Learned to make braided hoses yesterday. Not as hard as I thought it would be and they turned out pretty good.

 

Fuel cell is mounted in the stock location and holes were cut in the bed for filler and return line access. Once the hitch is mounted, it will all but disappear under there.


Front dress will be the late model stuff. It's ugly, but it works. The DIS coil mount will need to be reconfigured to work with the mechanical water pump and accessory drive brackets though.

 

Mocked up the intake to make sure it is all fitting like it should. Looking good to me. The coil bracket in front of the throttle body needs to be shortened about 1" to fit correctly.

 

Started thinking about the mount for the turbo. The cardboard is just a rough idea, but I think I have a pretty good idea of what I want to do. The flange needs to be at an angle to give the exhaust a straighter shot and to leave spark plug access, but if you put too much on there, that causes the turbo to sit waaaay out there. It will bolt in two places on the front for the majority of the load carrying and be stabilized by the back bracket tying into the engine side of the motor mount.