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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: September 10, 2016 05:23PM

It looked like it would work well enough as far as fit went, but I began to hate the way it looked- way too many fittings, and not clean enough. I've gotten pretty good at bending and flaring stainless lately, so I thought I would try and see if I could do something cleaner using hardline. This is what I came up with:

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: MattNall ()
Date: September 10, 2016 06:11PM

Makin' Headway!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: September 18, 2016 12:19PM

When I went to assemble the braided hose that was to connect the open ends between the fuel filter and rail, I discovered that there was no room for the
braided hose, as the adapters and swivel ends took up all of the room. ARRRG!
I settled on a slightly different way to do that connection, and although I'm not entirely happy with the "aiming" of the lines, this will work for now.
I've got the entire system hooked up now, and all fittings tightened up. Next thing to do is test to see how many leaks I have gggg. Here's some pics!!

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: caroseiii ()
Date: September 19, 2016 07:44AM

...Maybe too much plumbing. I am trying to think of ways to keep all of that out of sight in order to avoid crowding.
Crawford

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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: September 19, 2016 10:09PM

I agree, too much plumbing- fortunately, the air cleaner does cover that stuff.
It is easy to work on, and make changes, and this by itself has been something
that I've come to appreciate- the set-up I had previous using the braided stuff, was an absolute nightmare to work on. There was barely enough room to get wrenches on the few fittings that it had, and then on top of that there wasn't enough room to hold a fitting while tightening, causing the line to want to twist. The braided stuff tends to only look good for a few months and then dust get's into the wire and looks "old" and is difficult to clean. It is also much more fragile than I would have thought, and not nearly as flexible as I would have liked. I ended up swapping it out (and ditching the deadhead
approach) because I found a seeper type leak on the fitting that enters the rail... no way to fix that easily without starting over again on a new rail, as the npt threads had gotten over tightened to "aim" the fitting better- ruining the threads. I figured that since I was going to have to re-do all that stuff anyways, I was going to get rid of the deadhead system, as I felt it
was causing me problems, and besides, by then, I had developed a hankering
for stainless hardline- perfect excuse to re-do it.

Anyways, its looking a bit clunky to me, particularly the cross over part at the shroud, and the funny business at the filter. I stopped working on those
because I ran out of tubing, and changed my mind too many times. I'm thinking
the cross over pieces would look a heck of a lot nicer if it was one piece, and lower- simple to do when I get some more tubing. I thought all this stuff
would work out well enough for temporary but its beginning to look like I might
be changing it again, as I've got a nasty leak in the fuel rail- I might have to build another one- looks like the injector pockets got dinged while I've had it apart.... arrg!!

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: September 27, 2016 10:08PM

It turned out the gusher leaks I had from the rail were caused by the rail getting tweaked/tipped over from the fuel filter/flex hose not providing enough give... I ripped it out, started over again on that side, and fortunately did not have to make a new rail, just re-configure the connections.
This set-up doesn't need any braided line, there's adequate length to provide enough give in it now. The 90 degree fitting on the end of the fuel filter will be connected to the other end of the rail, so as to provide the necessary
compliance.

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 03, 2016 09:37PM

Got it done! I ended up making a new fuel filter feed tube, mostly to sorta match the shape of the line on the rail, and to tuck the tube under the filter a little better, and to lower the filter a little bit. I had to get that line
feeding the filter right, and be happy with it before bending the last piece,
so I could be sure of the positioning for the rail feed tube. The last picture
shows the last and most scarey bend of the whole thing for me... if I got that
bend in the wrong spot, there wouldn't be any real way to put it back in line with the fitting at the filter, except to start over again on a new piece. That
last piece was the only one I got right on the first try!

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 07, 2016 09:30PM

When I originally made the drivers side rail feed line, I had it kicked out to the side, like this picture shows, creating a crowding problem.

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 07, 2016 09:33PM

when I made the new piece, I tucked it straight down, under the rail, like this picture shows, getting me some more room on that side, and kinda sorta hiding the line a bit.... the trouble was, the other side didn't look like that!

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 07, 2016 09:37PM

The passenger rail feed looked like this, kicked out a little to match the original, and was now looking a bit weird to me, but I did have 40" left of
tubing to try a much more difficult piece to bend if I wanted...

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 07, 2016 09:42PM

I thought this would be a cool piece to try, as then I could delete another
fitting/adapter piece and perhaps tuck it in kind of like the other side, and perhaps gain a bit of room at the exhaust...

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: MattNall ()
Date: October 07, 2016 09:42PM

Looks good from here!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 07, 2016 09:48PM

I think it would be slick to make a set of tube separators, that have mounts to
attach some heat shields. might have to try that!! I think the next most important thing to do though is to deal with relocating the battery cable, manifold pressure sensing line/ boost gauge line and see if I cant mostly hide those items.

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: Lane66m ()
Date: October 08, 2016 06:42AM

Just curious why the aluminum fittings (blue fittings) on the stainless lines and components. Susceptible to corrosion due to material differences and prone to cracking (long term effect) due to temperature changes in the compartment.

Just trying to get some reasoning on making my Monza fuel lines and filter & pump install. I like the threaded connections to the filter. It was a thought I had while thinking out my system from tank to carbs (or EFI).

Al Lane
Ellabell GA

1966 Monza Coupe, 110 hp, 4 Spd
1966 Corsa Turbo Coupe, 180 hp 4 Spd
1964 Greenbrier Deluxe, 6 dr, 80 hp car engine, PG
2015 Chevrolet Malibu 2LT
2015 GMC Sierra SLT Crew Cab
1968 Camaro SS Coupe 350 CI 295+ HP PG
1947 Farmall A tractor 15 hp


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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 08, 2016 09:07AM

Basically, I ended up with alumimum fittings going up to stainless hardline mostly for cosmetic reasons , and because the aluminum fittings are much easier
and less expensive to get, and its just plain difficult to go all stainless all the way through the system.... stainless threaded fittings onto stainless have their own issues with galling and low oxygen corrosion also, so it isn't necessarily a ideal to use all stainless all the way through (although it can certainly work well when done with care). I would have liked to used stainless tube sleeves and nuts for color consistency but I already had pieces in the system that were anodized blue aluminum and wasn't about to change those out, so I kept with the blue aluminum/stainless color theme as best I could. The big real world concern with stainless flares onto aluminum fittings is that it can take an enormous amount of thread torque to seal the connection because the flare wont conform to the male fitting easily.... the solution to that is to put soft aluminum AN crush washers between the S.S. flare and the aluminum fitting- I did this on all of these connections and they all seal up quite nicely without a lot of thread torque- I was amazed at how little torque it takes to seal these fittings when those special crush washers are used... huge difference!

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: Setterz54 ()
Date: October 08, 2016 12:21PM

Fantastic work you have done putting all this together! It really looks great!

Setterz54
Fulton,MD.

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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 09, 2016 08:26AM

Thanks Setterz54 and Matt!!



Lane66m Wrote:
-------------------------------------------------------
> Just curious why the aluminum fittings (blue
> fittings) on the stainless lines and components.
> Susceptible to corrosion due to material
> differences and prone to cracking (long term
> effect) due to temperature changes in the
> compartment.

I think I was a little more worried about temperature concerns before I actually tried this, and although I do need shield the turbo, and shield the
lines near the turbo- my experience so far has been that the entire fuel system
runs much cooler than anything else in the engine compartment (basically ambient), and, with the exception of the rails themselves, pretty much runs at the same temperature. From what I remember, with the engine running, the rails
seemed considerably hotter than ambient, but I could touch them. With the engine off after running it for 15 to 20 minutes, they were WAY too hot to touch!!. I expect that with this full loop return style configuration, that the rails will run pretty much at the same temperature the rest of the fuel system because of the much enhanced cooling from the fuel, as most of the fuel, most of the time is flowing through the rails and back to the tank. Doing it this way, of course does eventually heat the fuel up in the tank, so anything I can do with shielding the lines in the engine compartment goes a long ways to limit the heat transfer to the fuel.

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 23, 2016 06:41PM

I thought it was going to be so simple to re-locate the battery cable, and reorganize the fuel pressure boost compensating line and generally cleaning up that crowded corner... I cant believe how much time I've spent on that one little detail, just to clean it up a little. Anyways, I took care of the battery cable by machining a grommet/strain relief to contain the battery cable
and main wiring harness. The oil pressure gauge line, boost gauge line and fuel pressure boost compensating line all got re-routed and better hidden. The
fitting that I used to connect the boost gauge line and fuel pressure boost
compensation line is now mounted directly behind the fuel pressure regulator.

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: October 23, 2016 06:43PM

Here's a couple more pictures...

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Re: My 63 Turbo, daily driver, various project pictures
Posted by: 63turbo ()
Date: November 24, 2016 10:10AM

Time for an update: I've had the engine running for a couple of weeks now, although I haven't driven it yet as I still need to complete my brake job- which has turned out to be far more involved than planned. I'm really glad I went ahead and took the time to take care of these annoying bugs this year- adding the air/oil separator, throttle linkage refinements, fixing the exhaust leak, putting in the full loop return/hard line fuel system, electrical wire re-routing, and others, even though it has meant basically not driving it for nearly a year. It turned out that some of these glitches, if not dealt with, could have resulted in a major heartbreak some time in the future.
When I originally put the new transmission link on, I didn't check that I was getting wide open throttle, but I noticed it wasn't closing all the way- I thought "no problem, I can adjust that"- this was a huge mistake, as the throttle was not even close to going all the way open and it refused to go into boost- DUH!
The interesting thing, aside from the obvious running issues that it caused,
was why and how the linkage wasn't allowing enough throw-the resolution of this
probably saved my bacon!!!

After it was clear to me that the linkage wasn't throwing enough, and it was not a adjustment thing that I could take care of from the engine compartment side, I got under the car to do some investigating, and it turned out that the
throttle rod was hitting the suspension when closed (preventing full closure)
and this same positioning was also causing the transmission link to hit the suspension when moving the throttle open, restricting the throw in that direction also. I didn't understand why the throttle rod would be hitting the suspension when closing- maybe I bent the throttle rod sometime in the distant past or something, but I ended up cutting a notch in the transmission link to give more upward throw, taking care of the immediate problem of lack of throw.
The next thing I discovered scared the KRAP of me! Now the throttle goes wide open, and closes all the way, but I noticed that something else was hitting when the throttle is opening, and that something was the battery cable to the starter, which had been re- routed because the injectors were in the way of the cable's stock routing. The cable routing had always been that way since the EFI conversion, so basically, every time I went to wide open throttle, the
throttle rod was rubbing on that cable, and if I hadn't caught that, it would have only been a matter of time before the rod rubbed through the cable insulation and caused a massive welder like short... at wide open throttle.

------------------------------------

Kevin Nash
Friday Harbor Washington
63 Spyder, Daily driver, EFI read about my project here: [corvaircenter.com]
first test start on EFI here:[www.youtube.com]
first official EFI boost test here:[www.youtube.com]
My new fan! [corvaircenter.com]
engine less 62 Spyder
Canadian 64 Monza Parts car



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Current Page: 16 of 18


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