Hi - Happy New Year to all - I have been rattling on about my fuel rail for what seems an age now, but I have finally got something finished and ready for my car!

 

Just to recap:

I wanted injector choice using top feed Bosch style injectors.

I considered the 300degree rails (and others) a poor solution (for me).

I wanted parallel fuel feed options.

I wanted to prevent thermally conducted engine heat from the engine warming the fuel delivery system.

I wanted to be able to change injectors easily without plenum removal.

I wanted a fuel rail that could grow with my engine as it changes and becomes more powerful. (This system is good for up to 1600cc injectors)!

I didn't want to have to modify my engine too much! (Just the lower plenum).

 

I promised some pictures so...

These are the fuel rails test fitted to the lower plenum which has the custom injector bungs fitted.

 

The bungs look like this:

 

Here you can see the rails with the injectors test fitted - on the bench so to speak:

 

This is what it's all about - 555cc RCE injectors, as used by many race teams - £35.00 each NEW 1000cc RCE injectors are £75.00!!!

 

A couple of shots of the rails attached to the lower plenum:

 

The rails are joined and held in place by two phenolic blocks (non heat transfer material) that are also holding two brackets that hold the rails down via 4 x new (upper plenum fixing) bolts. (they are going to get covered in Carbon Fibre probably so.. :thumbup1:)

 

Couple more shots:

 

...

 

 

This cut out of the front block is for the throttle cable to sit in...

 

absoloutly amazing :shock: can you make me one? :rofl:

 

 

 

 

That's it for now - will post complete install and finished engine as soon as possible - any questions please fire away..

 

Andy

These rails will prevent the use of the standard throttle cable cover, and also will not work with the cruise control in place either.

 

The core is 15mm all the way with -8AN threads on the legs and rail ends, although I have opted for -6AN fittings as I am currently only using 555cc injectors.

absoloutly amazing :shock: can you make me one? :rofl:

 

Did not make it myself - bought it :clap::thumbup1::euro:

wow very nice!! :thumbup1:

Did not make it myself - bought it :clap::thumbup1::euro:

 

ooooo... where and how much?

About 1000 USD plus taxes/duty - more details coming soon...

Well done bud, Thats fantastic!!!! I want!!! :drool:

 

Daz

A lot of flippin work Daz - I hope it's worth it!!

Fantastic work buddy, always amazing to see what you guys get up to! :D

This orange seal helps insulate the injector body from physical heat transfer from the lower plenum via the injector into the fuel rail.

 

 

looking good Andy, how have you got round the fuel line and temp sensor issue?

 

 

EDIT: scratch that, i've just seen your rail post :)

Edited January 4, 201015 yr by silverbullet

Hi matey: Apparently their is no ref to the fuel temp sensor (standard ECU - JD Chip) other than related to the PRVR - which I have already deleted, so I could ground the sensor and be done with it.

 

However, I have for now made provision for it to live here - the other side of the fuel filter and in line to the rail feeds for now. Once the car is running sweet again, I will probably just ground it, and replace/fit an external separate fuel temp gauge altogether.

 

The stock sensor screws right in there - which is a good thing at least. ;-))

What's So Special About Top-Feed Injectors?

 

* Lower price than side-feed injectors.

 

* Top-feed injectors are available in 1000, 1200 and even 1600 cc/min flow ratings which opens up the potential to make well over 1000 RWHP with one injector per cylinder in a six-cylinder engine.

 

* Peak and Hold coils, only available in top-feed injectors, are capable of drawing more amperage to create a stronger magnetic field, this makes the actuator respond faster than stock-type Saturated coils by as much as 1.5 Ms. Once opened, the injector needs much less amperage to remain open – using an injector driver such as AEM’s 30-2710 will allow full opening current and then reduce the power after opening. It is not advised to use resistors with Peak and Hold injectors; resistors will reduce the voltage (and therefore amperage) negating the Peak and Hold benefit almost entirely.

 

* The disc-type actuator weighs only 0.4 grams allowing it to open and close quicker than heavier pintle or ball type actuators; this allows cycle periods as low as 1.0 Ms and safe duty cycles approaching 92%.

 

Combined, these attributes add up to the ability to use high flow-rate injectors with brutal HP potential while maintaining decent low speed drivability.

Looking very good there Andy.

Managed to complete the balance bar modifications today and get stuff coated.

 

I have done [many] test fits and this all works out great now. For those who have not been watching, my custom high level fuel rail sits above the plenum and in order for the rails to exit correctly at the rear of the engine - the balance bar had to get some surgery.

 

Here is a stock balance bar with the new modified one above it in RED.

 

 

As you can see there is quite a difference!!

Have adopted -8AN fittings (x3) on the bar, same as the stock 1/2" bore.

 

Here is the passenger side:

 

 

And the centre take off's: This section had to be cut out and rotated, then the bungs were welded in.

 

 

 

That's my only update for now - tooo much work - not enough play ;-(

Great stuff loving this thread. It's good to see loads of pictures and explanations of what your doing and why. Makes me get off my arse and work on my own car when i can't see the end of the tunnel :bow:

can i ask you where you got the injectors from ? because im interested in buying some for my one. cheers

Pixas - they won't fit in your standard ZED - they are top-feed not side feed.

ah alright mate :p thanks for that :d

One of the reasons I went for a high level rail mod - so I could convert to top feed injectors and get more choice/options regarding injectors. And much better prices. ;-)

Great stuff loving this thread. It's good to see loads of pictures and explanations of what your doing and why. Makes me get off my arse and work on my own car when i can't see the end of the tunnel :bow:

 

Thanx Rubble - I agree - I am always inspired by the guys on here who take the time to share and educate people like me, and I am honoured you feel the same regarding my modest posts. Thanks again. :cool2: