The Widow Maker (Newage 2.5 cdb build)
Should take the manifold etc in to work dave, so it will be perfect then 
(not that I'm saying your drawings aren't).
How hard would it be fitting the rails on to mine later on in the year with everything in my car 'as is'?
(not that I'm saying your drawings aren't).How hard would it be fitting the rails on to mine later on in the year with everything in my car 'as is'?
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
My drawings are rubbish (the lads always laugh at them 
). Wish I could take the manifold in but would probably get the sack! I'm not going to drill the top holes until I've double checked the fit tomorow so it should be alright. The lads that are making them up are amazing at what they do.
Rails are easy enough to make up and won't be a problem to fit if you stay with your manifold (everythings always easier second time round).
You need to stop wasting money oo fancy rails and get saving for that 2.5 or stoker kit
! Thats why I'm skint, keep buying gauges and red buttons instead of the bits I need 
.
). Wish I could take the manifold in but would probably get the sack! I'm not going to drill the top holes until I've double checked the fit tomorow so it should be alright. The lads that are making them up are amazing at what they do.Rails are easy enough to make up and won't be a problem to fit if you stay with your manifold (everythings always easier second time round
). You need to stop wasting money oo fancy rails and get saving for that 2.5 or stoker kit
! Thats why I'm skint, keep buying gauges and red buttons instead of the bits I need .
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From: 5 beats 4 - RS3 Rulez!!!
UK/EU fuel rail mounts do not fit a JDM Manifold, as has already been seen. You either adapt the bracket, or you buy JDM specific rails. 
The latter is what I ended up doing.
EMB,
I can't see how you could get them to fit, as the UK brackets are much narrower than the JDM manifold holes. Regardless of how you mount the rails.
Dave,
Looking good!
The latter is what I ended up doing.EMB,
I can't see how you could get them to fit, as the UK brackets are much narrower than the JDM manifold holes. Regardless of how you mount the rails.
Dave,
Looking good!
UK/EU fuel rail mounts do not fit a JDM Manifold, as has already been seen. You either adapt the bracket, or you buy JDM specific rails. The latter is what I ended up doing.
EMB,
I can't see how you could get them to fit, as the UK brackets are much narrower than the JDM manifold holes. Regardless of how you mount the rails.
The latter is what I ended up doing.EMB,
I can't see how you could get them to fit, as the UK brackets are much narrower than the JDM manifold holes. Regardless of how you mount the rails.
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From: MY 10s blobeye 10.87@132 2.35/TO4Z next
Why couldn't Carl make you a set of Billet rails for the JDM inlet manifold?
Or did you order the wrong ones?
As for my turbo...T04Z capable of 650bhp(ish)
Check my thread below...you might be suprised!!
https://www.scoobynet.com/projects-4...o-project.html
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
Fai, I wasn't sure I could get a spec c manifold so orderd Carl's standard rails just in case I need to reuse my uk manifold. I'm also lucky to have access to a very good machine shop so was easier (and cheaper) for me to get adaptors made (would have had to send my manifold to Carl etc for him to make them up and I'm guessing it wouldn't have been cheap for a one off job like this, there was also time restrictions, I picked the manifold up two weeks ago and everything has to be ready for this Friday when I drop the car off at Pennine).
Dave
so was easier (and cheaper) for me to get adaptors made (would have had to send my manifold to Carl etc for him to make them up and I'm guessing it wouldn't have been cheap for a one off job like this, there was also time restrictions, I picked the manifold up two weeks ago and everything has to be ready for this Friday when I drop the car off at Pennine).Dave
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
Been a weeks delay 
, gives me a bit more time to sort out the fuel pump tho. Need to get pics up of new adaptors as soon as I can get a minute (everythings a bit hectic at the moment) and make a start on the brakets for the oil cooler. Hope to drop the car off on the 22nd now and pick up a week later.
If I leave you my car/garage keys will you put some miles on her for me when you get back while I'm at work.
, gives me a bit more time to sort out the fuel pump tho. Need to get pics up of new adaptors as soon as I can get a minute (everythings a bit hectic at the moment) and make a start on the brakets for the oil cooler. Hope to drop the car off on the 22nd now and pick up a week later. If I leave you my car/garage keys will you put some miles on her for me when you get back while I'm at work
.
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and to think a few weeks ago it was red standard and sat under my bonnet, cracking work mate. fair play for figuring out the fuel rails
what is your finished plan for the car?
what is your finished plan for the car?
Made a little more progress over the past few days on the adaptors for the spec c manifold.
For those that haven't seen yet I'm going to fit a spec c inlet manifold which is a 1 piece item without the 'tumbler deletes'.
- The benefit of this is the extra room it provides where the intake pipe fits onto the turbo (the standard type uk manifold can 'nip' a 76mm pipe, caused by the bolts whcih hold the intake to the tumbler deletes, this can reduce flow). This isn't a problem if you go rotated but my budget wouldn't stretch to this
.
- The drawback of the spec c inlet is that the rail fixing points on the spec c manfold sit lower down and I couldnt find and any aftermarket spec c rails.
Injectors landed on Saturday so was able to offer them up and measure what I need for the adapters. See pics of rails and injectors fitted:
See copy of sketch for adaptors:
Adaptors were started today, should get them tomorrow to test fit before we carryout the final machining. I'll put a better copy up of the drawing once I know they fit in case anyone else goes the same route.
For those that haven't seen yet I'm going to fit a spec c inlet manifold which is a 1 piece item without the 'tumbler deletes'.
- The benefit of this is the extra room it provides where the intake pipe fits onto the turbo (the standard type uk manifold can 'nip' a 76mm pipe, caused by the bolts whcih hold the intake to the tumbler deletes, this can reduce flow). This isn't a problem if you go rotated but my budget wouldn't stretch to this
.- The drawback of the spec c inlet is that the rail fixing points on the spec c manfold sit lower down and I couldnt find and any aftermarket spec c rails.
Injectors landed on Saturday so was able to offer them up and measure what I need for the adapters. See pics of rails and injectors fitted:
See copy of sketch for adaptors:
Adaptors were started today, should get them tomorrow to test fit before we carryout the final machining. I'll put a better copy up of the drawing once I know they fit in case anyone else goes the same route
.
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
Cheers, plan is for a bit of track us (nothing major) and a few trips to Elvington . Your build seems to be picking up speed, make sure you post pics of your new parts and progress (its nice to see what else is on the market. I've got a lot of my ideas and bought things from what I've seen/read on this forum .
. Your build seems to be picking up speed, make sure you post pics of your new parts and progress (its nice to see what else is on the market. I've got a lot of my ideas and bought things from what I've seen/read on this forum .
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
Fai, Power Enterprise injectors (800's) from Lateral.
Duncan, the fuel pump issue is still up in the air, for now I want to run a high flow pump in tank with the intention of fitting a swirl pot and second pump in the engine bay in a couple of months.
The two options for in tank seem to be a Bosch 044 or a high flow walbro both will replace my walbro 255. Does anyone have any experience of the high flow walbro's?
Duncan, the fuel pump issue is still up in the air, for now I want to run a high flow pump in tank with the intention of fitting a swirl pot and second pump in the engine bay in a couple of months.
The two options for in tank seem to be a Bosch 044 or a high flow walbro both will replace my walbro 255. Does anyone have any experience of the high flow walbro's?
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From: 700+ WR1 aka The Vuvu Zela...10.6 @ 136 weighing 1370kg....say no more....
Cheers.
My headers were used too but not too old. They first put all the parts through a industrial washer for cleaning before the ceramic coating process is undertaken. Lets say Chy is happy with the end result.
Mine should be ready very soon, hopefully to make space for your's.
Chy is very thorough indeed and I will be happy when he says it's ready. Speak to Chy about the fuel rails if your's aren't sorted as yet as he is sorting something out for me. Your 800 injectors may be modified so would be able to flow more.
I will give you a shout as the test runs will be carried out at Elvington which is where I will also be hooking up with a couple of others including Banny.
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
Cheers JP, would be good to meet up and have a look at your cars (steal some ideas ). Adaptors are nearly finished for rails now so should be o.k. What rails are you fitting, what fuel pump set-up are you going for?
I tend to use the car as a toy and take it off the road as soon as they bring the salt out, was going to spend the winter months tweaking things (coating the headers, downpipe etc would be one of these things), just want to get things running for the summer for now.
). Adaptors are nearly finished for rails now so should be o.k. What rails are you fitting, what fuel pump set-up are you going for?I tend to use the car as a toy and take it off the road as soon as they bring the salt out, was going to spend the winter months tweaking things (coating the headers, downpipe etc would be one of these things), just want to get things running for the summer for now.
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From: MY 10s blobeye 10.87@132 2.35/TO4Z next
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cheers mate
my build came to a bit of a halt whilst waiting for parts to arrive and engine porting balancing etc has been taking place, but evrything is back now so should start picking up speed. its hard not to become impatient, but best things come to those who wait
my build came to a bit of a halt whilst waiting for parts to arrive and engine porting balancing etc has been taking place, but evrything is back now so should start picking up speed. its hard not to become impatient, but best things come to those who wait
Cheers, plan is for a bit of track us (nothing major) and a few trips to Elvington . Your build seems to be picking up speed, make sure you post pics of your new parts and progress (its nice to see what else is on the market. I've got a lot of my ideas and bought things from what I've seen/read on this forum .
. Your build seems to be picking up speed, make sure you post pics of your new parts and progress (its nice to see what else is on the market. I've got a lot of my ideas and bought things from what I've seen/read on this forum .
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From: 700+ WR1 aka The Vuvu Zela...10.6 @ 136 weighing 1370kg....say no more....
Dave - On the rails it's a Chy special...even I'm not previleged to this info! As for the pumps it will be twin uprated walbros -you could wait and see how mine works out before you make your mind up whether to go with these or bosch, Chy is happy with them so I shouldn't think we'll encounter any probs.
Fai17 - Will give you and Dave a shout on the testing date as Chy will be sorting this out. It may be a "Pennine Scoobs Team" outing!
As for the pumps it will be twin uprated walbros -you could wait and see how mine works out before you make your mind up whether to go with these or bosch, Chy is happy with them so I shouldn't think we'll encounter any probs. Fai17 - Will give you and Dave a shout on the testing date as Chy will be sorting this out. It may be a "Pennine Scoobs Team" outing!
Last edited by JP4; Jul 12, 2009 at 10:18 PM.
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
Finally got round to uploading pics of adaptors, only have the top mounting holes to drill and tap. At the moment all measurements are still as shown on the original drawing:
Also fabricated bracket for regulator (to sit where the aircon was):
Also fabricated bracket for regulator (to sit where the aircon was
):
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From: Slowly rebuilding the kit of bits into a car...
Hi Dave are you running Defi's ?
If you get both fuel pressure and boost gauges you can run the fuel gauge in differential mode.... this displays the pressure difference between boost and fuel, so ANY lack of flow capacity will show instantly and an alarm is triggered, (mine alarm is set at 3.9 bar runs 4 bar static).
The sensor replaces the gauge in the regulator port.
HTH
dunx
If you get both fuel pressure and boost gauges you can run the fuel gauge in differential mode.... this displays the pressure difference between boost and fuel, so ANY lack of flow capacity will show instantly and an alarm is triggered, (mine alarm is set at 3.9 bar runs 4 bar static).
The sensor replaces the gauge in the regulator port.
HTH
dunx
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
Cheers dunx, think I'll try that (wish I hadn't wasted my money on a air/fuel ration gauge now and bought a fuel pressure gauge instead, lol).
(wish I hadn't wasted my money on a air/fuel ration gauge now and bought a fuel pressure gauge instead, lol).
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hey dave,
im desperately trying to find some tall gt legs for my spoiler with no joy do you think whoever machined your brackets could make some legs for me??
im desperately trying to find some tall gt legs for my spoiler with no joy do you think whoever machined your brackets could make some legs for me??
Made a little more progress over the past few days on the adaptors for the spec c manifold.
For those that haven't seen yet I'm going to fit a spec c inlet manifold which is a 1 piece item without the 'tumbler deletes'.
- The benefit of this is the extra room it provides where the intake pipe fits onto the turbo (the standard type uk manifold can 'nip' a 76mm pipe, caused by the bolts whcih hold the intake to the tumbler deletes, this can reduce flow). This isn't a problem if you go rotated but my budget wouldn't stretch to this.
- The drawback of the spec c inlet is that the rail fixing points on the spec c manfold sit lower down and I couldnt find and any aftermarket spec c rails.
Injectors landed on Saturday so was able to offer them up and measure what I need for the adapters. See pics of rails and injectors fitted:
See copy of sketch for adaptors:
Adaptors were started today, should get them tomorrow to test fit before we carryout the final machining. I'll put a better copy up of the drawing once I know they fit in case anyone else goes the same route.
For those that haven't seen yet I'm going to fit a spec c inlet manifold which is a 1 piece item without the 'tumbler deletes'.
- The benefit of this is the extra room it provides where the intake pipe fits onto the turbo (the standard type uk manifold can 'nip' a 76mm pipe, caused by the bolts whcih hold the intake to the tumbler deletes, this can reduce flow). This isn't a problem if you go rotated but my budget wouldn't stretch to this
.- The drawback of the spec c inlet is that the rail fixing points on the spec c manfold sit lower down and I couldnt find and any aftermarket spec c rails.
Injectors landed on Saturday so was able to offer them up and measure what I need for the adapters. See pics of rails and injectors fitted:
See copy of sketch for adaptors:
Adaptors were started today, should get them tomorrow to test fit before we carryout the final machining. I'll put a better copy up of the drawing once I know they fit in case anyone else goes the same route
.
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From: STI V8 with 558bhp 580ft/lbs on V-Power (2.5 cdb)
We only have basic machines and would struggle machining something as complex as spoiler struts, sorry mate. You need someone with a cnc or flowjet machine really, both would have the accuracy you need.
I'm not sure where your based but there must be someone local to you. Yellow pages - machine shops?
Sorry I couldn't help more.
I'm not sure where your based but there must be someone local to you. Yellow pages - machine shops?
Sorry I couldn't help more.
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From: 700+ WR1 aka The Vuvu Zela...10.6 @ 136 weighing 1370kg....say no more....
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From: 2.1cdb, gt30 billet, syvecs
.
Fai17 - Will give you and Dave a shout on the testing date as Chy will be sorting this out. It may be a "Pennine Scoobs Team" outing!
i will be up for that.
andy h
i will be up for that.
andy h
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From: home
I envisage a slight problem, and you need to make a slight revision to the adaptors...
The rails need to sit much further down. The o-ring on the top of the injector needs to be fully inside the bore of the fuel rail, and the injector needs to be bottomed out in the rail, or the rail needs to be just flush with the top of the plastic portion of the injector.
Otherwise fuel will leak out, and/or the injectors will be blown up out of the manifold so air starts leaking past them.
The rails need to sit much further down. The o-ring on the top of the injector needs to be fully inside the bore of the fuel rail, and the injector needs to be bottomed out in the rail, or the rail needs to be just flush with the top of the plastic portion of the injector.
Otherwise fuel will leak out, and/or the injectors will be blown up out of the manifold so air starts leaking past them.