IMG_2830.JPG
169 hits | 72.5 KB | Posted: 3/10/16
The more angled holes rode a little so I had to ream them later but it wasn't much of an issue.
(Posted in: Megasquirt fuel injection)

IMG_2831.JPG
162 hits | 67.53 KB | Posted: 3/10/16
Eight holes all drilled. Just need to make a quick fixture to hold the bungs properly.
(Posted in: Megasquirt fuel injection)

IMG_2881 (Edited).JPG
111 hits | 45.38 KB | Posted: 5/20/16
Driver's side bungs welded.
(Posted in: Megasquirt fuel injection)

IMG_2882 (Edited).JPG
130 hits | 50.87 KB | Posted: 5/20/16
Passenger side bungs welded.
(Posted in: Megasquirt fuel injection)

IMG_2883 (Edited).JPG
119 hits | 62.38 KB | Posted: 5/20/16
Fuel rail mockup.
(Posted in: Megasquirt fuel injection)

IMG_2884 (Edited).JPG
107 hits | 58.42 KB | Posted: 5/20/16
Bungs ground flush inside intake runners.
(Posted in: Megasquirt fuel injection)

IMG_2895.JPG
108 hits | 75.19 KB | Posted: 5/20/16
Intake bolted down and rails on checking for clearance.
(Posted in: Megasquirt fuel injection)

IMG_2896.JPG
135 hits | 61.26 KB | Posted: 5/20/16
Another shot of the intake and rails. Turns out the rails clear but not the fittings. Had to melt a little of the wiper box away but nothing too bad.
(Posted in: Megasquirt fuel injection)

IMG_2897.JPG
129 hits | 59.22 KB | Posted: 5/20/16
Custom chisel I made to fix the slight bulge the welder left in on bung.
(Posted in: Megasquirt fuel injection)

IMG_2967.JPG
101 hits | 49.32 KB | Posted: 5/20/16
Megasquirt bolted up behind the glove box.
(Posted in: Megasquirt fuel injection)

IMG_2968.JPG
105 hits | 51.15 KB | Posted: 5/20/16
View of the ECM from the passenger foot well.
(Posted in: Megasquirt fuel injection)

IMG_2969.JPG
129 hits | 68.05 KB | Posted: 5/20/16
Aluminum panel for fuse and relay blocks.
(Posted in: Megasquirt fuel injection)

IMG_2970.JPG
119 hits | 71.67 KB | Posted: 5/20/16
Electrical distribution center.
(Posted in: Megasquirt fuel injection)

FullSizeRender.jpg
121 hits | 62.25 KB | Posted: 6/15/17
Working on the wiring. I have the main relay and fuel pump relay half wired in this picture. You can see the wiring diagram I created (based on a Megasquirt diagram) that I'm using to wire everything. I only have 30 or so more wires to connect before...
(Posted in: Megasquirt fuel injection)

IMG_0556.JPG
118 hits | 75.42 KB | Posted: 7/2/17
Most of the fuel injection wiring harness installed. Took a long time but I tracked down factory connectors and terminals for every thing. There are no pigtails and almost no splices in the entire harness. It's just loosely zip-tied here but I'll pul...
(Posted in: Megasquirt fuel injection)

IMG_0603.JPG
94 hits | 63.7 KB | Posted: 8/15/17
Pulled the entire harness out of the car to wrap it up. The whole thing pretty much pops out as a single harness. All the wires terminate in OEM or at least OEM-style connectors. The Megasquirt 37-pin connector has to have the shell removed to fit th...
(Posted in: Megasquirt fuel injection)

IMG_0607.JPG
103 hits | 68.03 KB | Posted: 8/15/17
The harness fully wrapped in wire loom. Mostly high-temp split loom but there is some high-temp braided loom in there too. The high-temp stuff lets you use heat shrink on the ends for a clean finish. Everywhere the loom splits or changes size it's wr...
(Posted in: Megasquirt fuel injection)

IMG_0608.JPG
110 hits | 72.34 KB | Posted: 8/15/17
The tuning software running on the laptop talks to the ECM and the ECM talks to the sensors. I calibrated the TPS right after this but everything else looks normal.
(Posted in: Megasquirt fuel injection)

IMG_0609.JPG
131 hits | 63.97 KB | Posted: 8/15/17
Harness installed on the car. It hides pretty well. I was going for an OEM fit and finish and I think it looks pretty close.
(Posted in: Megasquirt fuel injection)

IMG_2849.JPG
89 hits | 74.71 KB | Posted: 8/15/17
Laying out the rails to hold the injectors for welding. 3/4" extruded aluminum square tube.
(Posted in: Megasquirt fuel injection)

IMG_2850.JPG
103 hits | 71.1 KB | Posted: 8/15/17
View from the driver's side.
(Posted in: Megasquirt fuel injection)

IMG_2851 (Edited).JPG
100 hits | 62.32 KB | Posted: 8/15/17
Better lighting. Short pieces of 1/2" threaded rod hold each bung and allow me to adjust the bung height pretty precisely. Had to make the cross pieces angled a bit to account for the angle of the carb mounting pad.
(Posted in: Megasquirt fuel injection)

IMG_2852.JPG
131 hits | 69.52 KB | Posted: 8/15/17
The lower nuts holding the bungs had to be ground down to 3/4" diameter to fit through the holes with the bungs. I ground flats on them so I could tighten them with a wrench. The bungs ended up withing a few thousandths of each other in height. ...
(Posted in: Megasquirt fuel injection)

IMG_2853.JPG
115 hits | 74.4 KB | Posted: 8/15/17
Everything bolted down and ready to go to the welder.Nothing moved much during welding so I suppose the fixture worked well. I still have the bits in case I ever end up doing this again. Not hard at all.
(Posted in: Megasquirt fuel injection)

bt2.JPG
102 hits | 37.66 KB | Posted: 3/8/16
The car has a convenient factory hole to run wires to the trunk. The factory trunk lighting wires run through here with no grommet so my battery cables should be fine in the flexible conduit I'm using.
(Posted in: Trunk mounted battery)

bt3.JPG
107 hits | 50.56 KB | Posted: 3/8/16
Flexible conduit run. This is all behind the rear seat and behind various panels and whatnot. It's invisible once the interior is in.
(Posted in: Trunk mounted battery)

bt6.JPG
126 hits | 41.73 KB | Posted: 3/8/16
Joining the flexible conduit to the battery box. I used a special bulkhead fitting. Should be nice and airtight once it's all said and done.
(Posted in: Trunk mounted battery)

bt7.JPG
173 hits | 45.33 KB | Posted: 3/8/16
Battery box vent. Hose plastic epoxied into the 90 degree bulkhead fitting and into the trunk sheet metal.
(Posted in: Trunk mounted battery)

bt8.JPG
137 hits | 77.29 KB | Posted: 3/8/16
The former battery location is full of air filter. Running the two cables through the conduit was not easy; it took a lot of lube but it worked out okay. The battery is grounded to the trunk floor and then to the frame in the rear and the engine bloc...
(Posted in: Trunk mounted battery)

bt1.JPG
93 hits | 78.94 KB | Posted: 5/20/16
Pile of parts ready to install.
(Posted in: Trunk mounted battery)

bt4.JPG
94 hits | 75.45 KB | Posted: 5/20/16
Flexible conduit running down channel by doors. Well protected.
(Posted in: Trunk mounted battery)

bt5.JPG
89 hits | 74.43 KB | Posted: 5/20/16
Conduit coming out in engine compartment. Came up through a factory hole.
(Posted in: Trunk mounted battery)

IMG_2549.JPG
95 hits | 37 KB | Posted: 5/20/16
Vent tube. Epoxied into the fitting and to the floor. No movement, no leaks.
(Posted in: Trunk mounted battery)

IMG_2559.JPG
154 hits | 74.95 KB | Posted: 5/20/16
Crimp fitting, solder to cover the open end, marine heat shrink to seal and act as strain relief. That's how I do it at least.
(Posted in: Trunk mounted battery)

IMG_2906.JPG
88 hits | 49.97 KB | Posted: 5/20/16
Pump and pre-filter mounted to frame behind fuel tank.
(Posted in: Fuel system 2016)

IMG_2907.JPG
107 hits | 47.3 KB | Posted: 5/20/16
Walbro fuel pump mounted.
(Posted in: Fuel system 2016)

IMG_2908.JPG
106 hits | 49.78 KB | Posted: 5/20/16
Pre-filter mounted.
(Posted in: Fuel system 2016)

IMG_2911.JPG
84 hits | 49.64 KB | Posted: 5/20/16
Heat/splash shield mounted over fuel pump. Pic upside down for some reason.
(Posted in: Fuel system 2016)

IMG_2938.JPG
90 hits | 75.36 KB | Posted: 5/20/16
Y-block on bracket to mount behind cylinder head.
(Posted in: Fuel system 2016)

IMG_2940.JPG
86 hits | 44.3 KB | Posted: 5/20/16
Y-block mounted on head. Pic from below.
(Posted in: Fuel system 2016)

IMG_2941.JPG
78 hits | 51.05 KB | Posted: 5/20/16
Fuel filter mounted and return line connected.
(Posted in: Fuel system 2016)

IMG_2942.JPG
73 hits | 55.5 KB | Posted: 5/20/16
Fuel pump and pre-filter plumbed.
(Posted in: Fuel system 2016)

IMG_2943.JPG
106 hits | 49.76 KB | Posted: 5/20/16
Filter and return.
(Posted in: Fuel system 2016)

IMG_2944.JPG
82 hits | 54.46 KB | Posted: 5/20/16
Fuel pressure regulator on bracket.
(Posted in: Fuel system 2016)

IMG_2945.JPG
95 hits | 68.98 KB | Posted: 5/20/16
Fuel pressure regulator.
(Posted in: Fuel system 2016)