psu_Crash Posted September 12, 2008 Report Share Posted September 12, 2008 (edited) First of I had to figure out how to get this IC in there ... it's quite a bit bigger, almost 5" thick! Looks like it's time to bust out the Sawzall! http://img440.imageshack.us/img440/8974/icnewvsoldzd8.jpg Gutted and ready for surgury http://img440.imageshack.us/img440/7910/guttedfrontclipxi5.jpg Many hours later the sun gave out on me. All went pretty well. IC and piping is in, Magna is in with most of the lines connected to it. I need to open up the holes I made for the IC piping a little more to give me some play to work with on the other side. Also have to cut the bumper mounts a little for it to fit back on. Going to be interesting getting it all hooked up to the TB and Turbo. My big problem right now is the fuel line. I can't seem to find a place to make a new one for me and haven' figured out a safe way to kook it up with what I have. I have a question too. The coolant line that comes off of the T on the hard pipe that goes around the pass side of the engine. That bottom line coming off where the heater core line meets the hard line should be routed to the fitting on the bottom of the thermostat housing right? Here is what she currently looks like, i have a lot of cleaning to do ... i know. More pics to come as progress it made. Should have it done in a few days!!! .... i hope That new IC sure sits low. Hoping the air dam will hide it. http://img440.imageshack.us/img440/5784/day1completeam2.jpg Edited September 21, 2008 by psu_Crash Link to comment Share on other sites More sharing options...
Technology Posted September 12, 2008 Report Share Posted September 12, 2008 (edited) At least you didn't have to cut your frame rails! Congrats. Edited September 12, 2008 by Technology Link to comment Share on other sites More sharing options...
Mingo1 Posted September 12, 2008 Report Share Posted September 12, 2008 It never sat that low on the car. Trying moving the oil cooler and maybe removing some of that center bracket. Link to comment Share on other sites More sharing options...
psu_Crash Posted September 12, 2008 Author Report Share Posted September 12, 2008 Got the bumper and air dam back on today and the IC hangs about an inch lower than the air dam ... kinda scary. But at least it is only one spot where the IC angles on the bottom. I cut holes for the IC piping as high in the front wall as I could to get the IC as high as possible so i think I am just going to have to live with it and be aware that it's there while driving. Technology I was reading the post on your install and where did you get that fuel line? I can't seem to find anyone who will make one for me. Another thing, can I just plug the tapped hole Chad put directly under the T Stat and then plug the coolant line that t's off one of the heater core lines that used to run through the old intake back to the thermostat? I planned to just put a fitting on there and run line across under the intake manifold but with the A/C bracket there it doesn't leave room for anything longer than maybe an inch. Thanks for your help! Link to comment Share on other sites More sharing options...
psu_Crash Posted September 12, 2008 Author Report Share Posted September 12, 2008 Mingo did I put the IC on the right direction? I see there was an L and R written on opposite sides. Thought about it for a minute and decided air would flow best the way it is, but i am often wrong Link to comment Share on other sites More sharing options...
substock Posted September 12, 2008 Report Share Posted September 12, 2008 i used that spare port for my temp gauge. so both of them are for gauges(megasquirt and aftermarket) then i just plugged that opening. i some have welded that shut while others(like me) used a big bolt and clamp Link to comment Share on other sites More sharing options...
Lusion972 Posted September 12, 2008 Report Share Posted September 12, 2008 I can't see the pics right now because I am at work and they block everything but I am happy that you are documenting everything so I can follow your lead. MORE pics please...lol Link to comment Share on other sites More sharing options...
Technology Posted September 13, 2008 Report Share Posted September 13, 2008 I drove around and found a place that specializes in hoses for industrial purposes. I brought some hose and the banjo ends and the guy there used a crimp piece and got them on that way. You can't buy the right size hose from napa or anything becuase it's metric sized ends on the banjos. You might need some metric hose (that's what he told me, but he just overdid it with slightly too large hose, bless his heart, lol). But my magna came with a fuel rail that had the banjo end on it, so I used the stock fuel line and cut it off to use that end, then traded ends so the OEM filter banjo now mounts to the fuel rail and vice versa. Link to comment Share on other sites More sharing options...
psu_Crash Posted September 13, 2008 Author Report Share Posted September 13, 2008 (edited) I had the banjo fitting on the fuel rail when I bought it. Brought fuel filter SS line and the banjo into work and my friend the pipefitter made up a line for me ... free. Now I have a couple more pics and some questions. The end of my fuel rail is very tight against the Heater core hose as you can see. When my engine rocks at all it is going to rub on that pretty hard. What should I do about this? http://img90.imageshack.us/img90/9093/fuellinehittinghosezk0.jpg Looks like some more bracket removal is in store. http://img134.imageshack.us/img134/9457/icpipehitbracketstb2.th.jpg http://img48.imageshack.us/img48/3271/icpipehittingbracketszx5.th.jpg I cut out the holes for the IC piping through the front wall and was able to get the IC up just above the air dam ... but still low. Hoping to get the IC pipes connected to the TB and Turbo tomorrow or monday for sure. Pics will follow Edited September 13, 2008 by psu_Crash Link to comment Share on other sites More sharing options...
StarquestRescue Posted September 13, 2008 Report Share Posted September 13, 2008 The end of my fuel rail is very tight against the Heater core hose as you can see. When my engine rocks at all it is going to rub on that pretty hard. What should I do about this? I am thinking get some silicon heater hose and loop it up over and than down. Link to comment Share on other sites More sharing options...
Lusion972 Posted September 13, 2008 Report Share Posted September 13, 2008 they have a set of silicon heater hoses that mookeeh is selling on ebay real cheap right now...I bought some in blew and will cut them down to size to fit mine. They take a beating better then the rubber hoses. Have you done the wiring part yet? Link to comment Share on other sites More sharing options...
Mingo1 Posted September 14, 2008 Report Share Posted September 14, 2008 Mingo did I put the IC on the right direction?Yep its in the right direction. It use to sit just right about the lower part of the airdam. Looking good. Link to comment Share on other sites More sharing options...
psu_Crash Posted September 15, 2008 Author Report Share Posted September 15, 2008 Have you done the wiring part yet? Yep wiring is done. Magna is all hooked up now .. i think. Find out for sure when I fill it up with coolant and it leaks everywhere because I forgot a line Still need to get the front back together but i am debating the location of the IC I think I can get it an inch or maybe 2 higher with some tweaking. Picked up some silicone hose for the heater core too. Have to see how that works out. Thanks Guys! More pics coming soon ! Link to comment Share on other sites More sharing options...
psu_Crash Posted September 17, 2008 Author Report Share Posted September 17, 2008 (edited) So the first thing I did today was grab the sawzall and get the IC to sit higher so that is all good now. Wiring is complete. Fuel line http://img295.imageshack.us/img295/508/fuellinein7.jpg The pipe I had for the turbo to the IC wasn't going to work for me so I took the OVCP and turbo to IC pipe that i already had and cut them a little shorter to fit. Worked like a charm! The MK1 parts actually fit much better like this than where they were meant for! http://img295.imageshack.us/img295/5800/ovcpforicas1.jpg NEW IC AND MPI IS ALL IN!!! Think I need to change my shorts http://img329.imageshack.us/img329/3658/mpiinstalled1bp1.jpg http://img295.imageshack.us/img295/5620/mpiinstalledok8.jpg But I do have one major issue. I lost the damn banjo bolt for the fuel rail. Anyone know where I can get one? I tried to use the one from the fuel filter but the threads aren't right. I am desperate to find one ASAP. I was sooo excited to start the car today and when I went to put the fuel line in realized I have no freakin idea what I did with that bolt. Looked around for a couple hours with the help of a couple of friends with no luck. I will hit NAPA, Autozone ..ect in the morning praying to find something that will work. I think I have MS all setup for everything too so all i need is that damn banjo bolt and I am ready to start her up! Someone please tell me where I can get one ... I am desperate Edited September 17, 2008 by psu_Crash Link to comment Share on other sites More sharing options...
psu_Crash Posted September 19, 2008 Author Report Share Posted September 19, 2008 (edited) Guy at work made this for me out of stainless 16mm stock. It fits perfect! ... Thank God http://img145.imageshack.us/img145/364/banjobolt002yu3.jpg I would like to add an electronic fuel pressor sensor to be read by MS. Anyone know a good place to get one at a decent price? Don't really hve the $$ for an autometer. This build was expensive! Can I use the stock oil pressure sending unit for this since I am not using that anymore, then tweak it with EasyTherm? Edited September 19, 2008 by psu_Crash Link to comment Share on other sites More sharing options...
substock Posted September 19, 2008 Report Share Posted September 19, 2008 Guy at work made this for me out of stainless 16mm stock. It fits perfect! ... Thank God http://img145.imageshack.us/img145/364/banjobolt002yu3.jpg I would like to add an electronic fuel pressor sensor to be read by MS. Anyone know a good place to get one at a decent price? Don't really hve the $$ for an autometer. This build was expensive! Can I use the stock oil pressure sending unit for this since I am not using that anymore, then tweak it with EasyTherm? glad you got that banjo made, i found last night at my parents 2 of them i forgot about i could have sent to you. Link to comment Share on other sites More sharing options...
psu_Crash Posted September 19, 2008 Author Report Share Posted September 19, 2008 O .. i see ... NOW you come though .. lol All is well, now I get to see if I can get her started ... gulp ... Link to comment Share on other sites More sharing options...
psu_Crash Posted September 21, 2008 Author Report Share Posted September 21, 2008 (edited) SUCCESS!!! Got it running today! Fired as soon as I hit the key and ran great!. Surprising since I hadn't changed anything in megasquirt since running on TBI. Ran rich but not terrible. I will get MS dialed in tomorrow I hope. So I connected MS to control the fuel pump since I eliminated a good bit of the stock harness. Now the pump runs all the time when the car is on instead of just while it's cranking/running. Is there a setting I am unaware of? So how am I supposed to fit the battery back in?? It doesn't fit at all. Time to relocate it? I already have 00 gauge wire running to the trunk from someone's amp install. I should be able to just hook the battery through that if I have to. Crammed it in this far but it's not all the way in and it's not happening. http://img502.imageshack.us/img502/7764/batterydoesntfityk5.jpg Edited September 21, 2008 by psu_Crash Link to comment Share on other sites More sharing options...
Lusion972 Posted September 21, 2008 Report Share Posted September 21, 2008 piping needs to be modified to fit up front....dont know about the fuel pump thing...I was gonna run mine off of a switch like boho has installed in his quest along with a push start button. Link to comment Share on other sites More sharing options...
Evil_Betty Posted September 21, 2008 Report Share Posted September 21, 2008 (edited) Instead of relocating your battery, you could always get a smaller battery. I believe Braille Auto makes some good, small ones. Just throwing out an option. I did a battery relocation once with 00(expensive back then, not sure now) and it was not worth it. Too much wiring, making sure everything grounds right, etc. I'm not sure about the fuel pump issue, mine runs from the stock wiring. You should be able to wire it directly to MS and have it only @ crank/run. Check the megamanual, has to be in there somewhere or in the MS forum. Good luck, it's looking good. Glad u got it running so quick. -Justin Edited September 21, 2008 by Evil_Betty Link to comment Share on other sites More sharing options...
chiplee Posted September 21, 2008 Report Share Posted September 21, 2008 Did you do anything to divide the top end tank between your inlet and outlet pipes? Even if you did I'm not sure what it would do to the intercooler's performance but if you didn't, then you're intercooler definitely isn't going to work as it was designed. Obviously the intent is that charge air from your turbo compressor housing pressurizes the top tank which forces air down through the narrow passages, where it is cooled, and dumped into the bottom tank cooler and more dense. It goes from there to the intake. What you did, assuming that top tank is not divided by a wall of aluminum inside, will allow a large percentage of your charge air to pass directly from the turbo to the intake, or directly through the top tank on your intercooler, without going through the narrow cooling passages at all. It will follow the path of least resistance when you build boost and it will be like not having an intercooler on your car. Link to comment Share on other sites More sharing options...
speedyquest Posted September 21, 2008 Report Share Posted September 21, 2008 i had noticed that also chiplee, but figured it had some kind of separation to force the air thru the entire intercooler... that lower tank looks so odd. Link to comment Share on other sites More sharing options...
psu_Crash Posted September 22, 2008 Author Report Share Posted September 22, 2008 (edited) The top tank has a divider in it so I think all is well! The lower tank is shaped like that to help force the charged air to use the most of the IC. I know it looks odd but at least in theory I get the idea. Edited September 22, 2008 by psu_Crash Link to comment Share on other sites More sharing options...
Mingo1 Posted September 22, 2008 Report Share Posted September 22, 2008 It worked on a 400hp quest ok 398 but it worked. Link to comment Share on other sites More sharing options...
psu_Crash Posted September 23, 2008 Author Report Share Posted September 23, 2008 Got MS tuned in enough to take it for a spin. WOW ....throttle response is soooo much better, it runs smoother, and it feels like there are 50 more HP!! With a little more tuning I just might be the newest 300+ HP club member!! Can't wait to blow my buddy's 275HP vette off the road. It will happen :hmm3grin2orange: Link to comment Share on other sites More sharing options...
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