FI Build-up - German Plenum/TB & MS-1

[Vee Dub Nut]

That looks lovely! Very nice neat job there!!

I have to admit though that that wiring diagram looks SCARY! Is it really as scary as it looks? Or is it actually kinda straight forward? Sounds like you might be playing with more than just the MS wiring.

Awesome stuff dude!

J

Thanks...

The wiring diagram is not too bad, thats just what you get when you draw it by hand. Everything is documented well online for all the wiring needed. I'm adding a few things in for good measure, but nothing too complicated.

[Vee Dub Nut]

Not too much happening lately... been busy with some other things, and I'm hung up waiting on some other parts so there hasn't much rush to finish the wiring. My plan is to get a good portion of it done on Saturday.

I did get the coil mounted. I purchased a set of Accel wires that were cut to length so I could mount my coil on the upper right firewall. I wanted to get some regular black or grey wires that wouldn't stand out too much, but my only choices were red or blue, so I picked the lesser of two evils. In the process of making a mount for the coil, I broke the used coil that I purchased from boostengineering, so I had to pick a new one up from my flaps..



The only thing I don't really like is the amount of wires I have in the engine compartment. It looks a little busy to me, but I'm used to pretty simplistic wiring with carbs and distributor. My wifey just laughed when I told her and she said "you can't have it all".. guess shes right

Should be running soon.. got my shipping notification from CB Perf that my exhaust is on its way, so finally the last few pieces are on the way.

[JSL56]

Great news dude! SO close!!!

Are you gonna get wifey to film the first start up?

I just recieved my CB manifolds and injector rails etc yesterday from 'Pherlopolus' on here! Wahoo! Im looking forward to mocking up the engine soon.

Cheers,

J

[Chris181]

Very nice work !

just a suggestion, be careful of your sensor bracket, I do the same and it 'move' with motor heat about 2mm
maybe not enough strong for me, but about 4mm in steel, maybe it's better in aluminium ??

[Vee Dub Nut]

Are you gonna get wifey to film the first start up?

Oh yea.. there will be some video's to come

[Vee Dub Nut]

Very nice work !

just a suggestion, be careful of your sensor bracket, I do the same and it 'move' with motor heat about 2mm
maybe not enough strong for me, but about 4mm in steel, maybe it's better in aluminium ??

thanks for the tips.. I'll keep an eye on it

[Vee Dub Nut]

Ahhh.. today was the day of the great zip tie massacre

Wiring is about 98% done... Don't have the LC-1 hooked up yet. My exhaust will be in on Monday, so I will be able to finish that up once its all mounted. Other than that, just a few small bits here and there to finish up.

All in all I'm pretty happy with it.. a lot of ups and downs through out the day. Spent a lot of time frustrated trying to tame all the wires, but eventually got them all tucked in and routed nicely.

On to the pics..

overall shot:



and a closeup of the action



I think it came out pretty good.. I'm a perfectionist and still wish I could tidy up the wires even more, but without making a large mounting board and spreading everything way out, I don't think it could be any more organized.

I did pull out the laptop to the garage and got hooked up to the MS. A turn of the key and "verrrrrrrrrrmmmmmp" the fuel pump went through its priming pulse and Megatune connected to the ECM!

I took a few minutes to check out some things. I verified that my TPS was working properly at closed and WOT, and that both temp sensors were reading correctly. I also saved the .msq that Mario had loaded for me, and checked out the VE and spark tables. Now I need to go reread the startup guide in the megamanual to refresh my memory on the first start steps.

Anyways.. except for the exhaust and putting the gas tank back in the car, Its just almost ready to start!

[yvre]

Nearly there! Keep the updates coming!

[Vee Dub Nut]

Well... for better for worse, I decided to go ahead and put the turbo on the car now. This means my completion will be pushed back a little bit, but my deadline is that the car has to be ready by the Texas VW Classic in April.

Goals:
Running a T3 turbo (looking to lift one off an older saab, AR.42/.48)
CB Hideaway header
Looking for low boost right now.. 5-7lbs, until I can build up the bottom end of the engine stronger
From my research and calculations, 7lbs should put me in the 150hp range

It will be interesting to see if my theoretical calculations match up in real life. Some new tasks for the project:

Modify my fuel pressure regulator to be boost referenced (http://www.dune-buggy.com/turbo/fuelsystem.htm).
Make a dump pipe for the turbo w/ my O2 bung installed into it.
Install my deep sump, and plumb oil feed and drain lines.
Replace my intake runner couplings with good silicon boost couplings.

Any other tips?

[ToRy 70]

Wow, super clean build. I have an unused boost-referenced regulator in my extra junk pile at home, I booted it when I went to AN lines. Let me know if you want it cheap... might not be home for a few weeks though.

Do you have a good set of bigger injectors?

[MarioVelotta]

Moving the wastegate from the #2 cylinder should be thought about. To the collector would be best. With low boost, the 24lb injectors will work. But over the 6 or 7 lb mark you will probably be pushing that duty cycle into the 90's. But you are only some tubing, plumbing and a turbo away at this point. Woot!!

Looking great BTW

[miniman82]

FYI, I'm at 10 psi boost with 35 lb injectors (375cc) on my 1915, with duty somehwere in the mid 70's if I remember correctly.

[Vee Dub Nut]

Wow, super clean build. I have an unused boost-referenced regulator in my extra junk pile at home, I booted it when I went to AN lines. Let me know if you want it cheap... might not be home for a few weeks though.

Cool.. I'll shoot you a PM. I can modify mine without too much issue, but depending on how cheap is cheap, I may save myself the trouble

Do you have a good set of bigger injectors?

Not right now.. From my calculations, I think that I may be ok with my 24lb/hr I currently have, but just barely. My plan is to try them first, and then adjust as needed. That is unless I find someone who needs a set of 24lb/hr injectors that I can sell mine too to offset the cost of another set.

[Vee Dub Nut]

Moving the wastegate from the #2 cylinder should be thought about. To the collector would be best. With low boost, the 24lb injectors will work. But over the 6 or 7 lb mark you will probably be pushing that duty cycle into the 90's. But you are only some tubing, plumbing and a turbo away at this point. Woot!!

Looking great BTW

Thanks sir... I'm hoping that I can just stretch the 24lb injectors right now. I'm not looking to make a ton of power, just make it more fun to drive while I save up for the big engine changes.

EDIT: oh yea... I forgot to mention that I already have the CB hideaway turbo header, so all I need is a turbo and a little bit of plumbing

[Vee Dub Nut]

FYI, I'm at 10 psi boost with 35 lb injectors (375cc) on my 1915, with duty somehwere in the mid 70's if I remember correctly.

Thanks for the reference point!