ABF 8 injector set-up

Right, so I don't clog up the "DTH Jenveys with 120mm trumpets which air box/socks" thread: http://www.clubgti.com/forum/showthread.php?t=215462

I thought I'd add a few pics here.
Basically, I wanted to run Jenvey ITBs, on 8 injectors...just because.

Where to start?
A few pics:

Decided to run 2 x transverse 1.8T fuel rails.
Powder coated one of them.




To make that fit the Jenveys, it needed a couple of alloy mounting plates making (Thanks to F2Stu for the info)




Overhauled 8 x 1.8T 180 injectors (ultrasonically cleaned, new seals etc)




Modified 1.8T fuel rail, with standard mounts cut off, new mounts TIG'd on and Jenvey remote injector mount lugs TIGd on




Jenvey remote injector mounts TIGd to alloy tubes



Complete assemblies tidied up and shaped to fit inside the bellmouths




Completed and powder coated




Stand-offs made to the correct length, and TIGd onto the modified fuel rail, all powder coated






Spacer plate made to support the outer fuel rail...one inside the backplate, one outside. Outside plate has 20mm Jenvey spacers TIGd to it.






Spacer plate onto DTH ITBs




Jenvey backplate on next




Next spacer plate on along with 60mm ram pipes - one modified to clear OEM 1.8T FPR housing




Fuel rail on






Filter on




Test fit




Just the fuel lines to sort out.
Engine loom completed - modified a standard ABF loom, changing plugs, wire length etc
It's all done now, along with additional wires for the remote injectors and coilpcack (wasted spark).


More to follow when I remember to take more photos.

 

Looks very well engineered.

What management will you be running?

 

Emerald K3 ECU, Jenvey throttle pot, Zetec coil pack, standard ABF AIT, CT, Cam position and crank position sensors.

 

Very nice work Ess and good to see some pics of this. The outter injectors seem like they could end up blocking airflow abit. Don't know if you'd have the space to mount these babes http://www.jenvey.co.uk/Imgs/Accs/AH51x125IM.jpg

 

Airflow could indeed be resticted slightly...but the cams aren't overly silly, so I'm hoping not.

The Jenvey horns with injector pockets put the fuel rail at too much of an angle to go under the filter...
The backplate and filter isn't much bigger width/height wise than an air horn...so a fuel rail wouldn't fit.
Making a bigger backplate wasn't an option as I'm limited by bonnet clearance.

What I am hoping, is that I can 'find' another 50mm-100mm out front - which it looks like there is...but going out also means going up slightly - where there isn't room.

So, adding curved spacers between the DTHs and the backplate solves the issue of bonnet clearance, fits behind the front panel...but hits the water connection to the head.

I heard today from my tame local fabricator, that my custom water connection is ready which should angle the water connection away from the backplate's underside...so all being well, I can:
Angle the whole filter assembly down by 22.5 degrees to clear the bonnet
Fit a far taller domed/box filter element and still get it behind the front panel
Space the outer fuel rail up 30-60mm to pull the injectors out to outside the bellmouths and maybe even to maybe allow 90mm air horns.

Time for another test fit...


At the end of the day, if it doesn't work, I'll unbolt the outer fuel rail, replace the modified air horn, and run it with inners only. 15 mins work max.

 

F**king ace

 

be interesting to see if inners + outers, vs inners, vs outers swings the power delivery about.

 

The assembly does look impressive and neat!
Keep them coming Glen.

 

You and Goof aren't the only ones working away behind closed garage doors accross the North East od Scotland!

 

The plan with running equal sized injectors to start with, is to map 3 ways whilst being able to supply enough fuel for every possible configuration:
Inners only
Outers only
Inners + outers, and play with the phasing point and bias.

Hopefully it'll answer a few questions with hard facts and results. Or not, as the case may be.

If I'm honest, I suspect I'm not running a high enough CR or high enough revs to see all the possible gains...but we will see.

I will also be playing with cams...
The plan is to try multiple combinations:
Schrick 268/std ABF
Schrick 268/268
Schrick 276/268
And see what's what. Ideally with adjustable verniers on to get the timing as best I/we can....then with cam selection fixed, play with injector phasing.

Sadly, dyno time will start getting expensive!

 

I shall try...
Many thanks for the guidance thus far!

Custom coil-pack bracket and HT leads this time home.
Photos to follow...

I'll maybe get the fuel lines and engine loom fitted too.

 

love it - nice experimentation

 

I cant see photobucket pictures from here

Q:are the 2 rails fueling in series or parallel?

 

Parallel.
Both running identical OEM FPRs, just tee'd off the standard supply and return nylon pipework.

*Edit*
Or they will be, when I buy a couple of tee pieces and make up the lines. I have the hose, the OEM clamps, seciring clips etc...just bo 8mm tees yet.
Maybe head to eBay now and look for some...

 

glen i was thinking about something like this but with the filter on the end of the airbox something like one bank of this

 

That would work if you could get a seal...
I couldn't see how to make it work with the bits I had or could lay my hands on.

You got any more ideas on how to get it all working through an airbox lid like that?

 

Anyone know where I can get a couple of 8mm T or Y pieces for fuel injection applications?

I'm not sure if a brass fitting would be OK...I'd assume so. Max pump discharge pressure must be 10bar ish...and you can use nylon hose/fittings at 10bar!

I've found plenty of brass fittings, but nothing FI specific.

*EDIT*
Found some, nylon, 14bar rated, petrol suitable.
Job's a good un.

 

imagining a GRP lid that would mate to the backplate you already have injectors poking through with O rings etc. would give you a bit more height potentially and not restrict the airflow to the trumpets

nice thick edge flange and a sheet of epdm rubber or something between back plate and lid flange

lower sketch is just an end on view

 

wow this should be good to see

 

Ahh...I get you.

Assuming I can get the filter backplate angled down to give me some more bonnet clearance, I guess it's possible to go in through an airbox lid.

I'll have a look...



Looks like there may just be room...

I guess you'd have to balance the gains from more remote mounting of the injectors outside an airbox lid vs longer trumpets under a domes filter with compromised remote injectors...
I don't think you'd get a big airbox on that would allow 90-120mm horns to be used, AND remote injectors, unless the front panel was releaved.

I'll have another look when I next test fit.