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88 Mustang LX
#21

(06-16-2020, 09:11 PM)TurboRay Wrote:  1. I wuz wrong once before, WSBUT......I'm reasonably certain that the turbine housing AND elbow are both made from cast STEEL, and - if so - might explain why yer flux-core welding wire "stuck". . [Image: confused0024.gif]

2. LINK  . [Image: happy0034.gif]

I'm not using a stock turbo. I've got a Holset that uses a weird flange and cast iron outlet adapter that I cut and welded to. Believe me, the initial few tacks gave me all kinds of trouble with cracking, but that's another story.

And I saw your post about adjustable regulators- that's what gave me the idea! I'll have to thank you for that. Unfortunately no one around here has any CFI units, and the ones online are going for $200+. Shame since I could use the larger injectors in them as well. But I took the same idea as that and just modified my own stock regulator. It wasn't too hard really and I was pretty pleased with the result.
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#22

Picture as promised.

Home brew adjustable fuel pressure regulator
   

Home made adjustable wastegate actuator
   

And an overall view of the janky turbo setup. Note the aforementioned VAM bracket from a chopped NA air cleaner bracket.
   
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#23

Got the GT fuel pump put in, and a new sending unit, so the fuel level gauge works for the first time since we had it. With all that done I took it out and it it drove like a dream. So much quicker even without really getting into boost. It felt like a decent car you didn't have to wring out just to get up to the speed limit. With the short downpipe and glasspack it also sounds beautiful. A bit of a Subaru rumble to it and lots of turbo noise. Not sure if I'm a big fan of that though. It sounds a lot meaner than a <150hp car should. I don't know how I ended up with a slow turbo four banger sounding so mean and a TT V8 monster that sounds like it's stock.

Getting into boost didn't go so well. It felt great, but it didn't take long for the cabin to fill with smoke. I quickly pulled over and got ready to extinguish it. I thought maybe my oil supply or drain lines I made had failed, but they were intact. Apparently under boost there was enough crankcase pressure to blow off the PCV hose by the distributor and make one hell of a mess. I guess the impactor/separator under the intake doesn't do much. I spend a good chunk of the day cleaning up the oil, and Ill have to revisit that line one way or another, even if it's just putting on a hose clamp to keep it secured. Let that be a lesson for anyone else doing an NA swap.
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#24

I clamped the PCV line for the time being and it seems to work.

Started working on the water/methanol injection system. I tested a few sprayer options with the new edge windshield washer pump and reservoir I have. The sprayer bar setup was far too coarse, no matter how small on the drillings you go. Little to no atomization. The ag sprayer was ok from a spray pattern standpoint, but even adjusted all the way down yielded a flow rate of 13 gph, far above the desired flow rate of 4 gph. I could try to orifice it down but I think that would hurt atomization even more. The home brew impingement nozzle faired the best. Basically just an orifice in a pipe plug with a nail ground into a point inserted into it. I'm going to start on that one with the tip being threaded on the opposite side of the pipe to allow for a degree of adjustment in flow and spray pattern.

The home made throttle switch is going to be a real abomination. But it ought to get the job done.
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#25

She's been on the back burner, but still doing work here and there.

The PCV issue was just a hint at a bigger problem. It was pushing oil into the charge system like nobody's business. I've since went to a vented catch can, made from a water bottle and some fittings. That resolved that.

I went intercooled using a junkyard intercooler. The inlet/outlets were not too desirable, but I made it work.

At the same time I threw the 79 front end I had laying around on it. It accommodated the intercooler much better. For those reading thinking of doing a four eye swap, don't bother running the four eye steel bumper. You have to change the mounts to the core support entirely. Much easier to cut some holes in the fiberglass one and make some brackets for the markers out of aluminum. The four eye hood has the scoop which would have been great with the top mount intercooler, but the front mount will be much more effective.

It had a nasty problem with boost leaks at the couplers. I went overkill on the size of the beads on it and that seems to have subsided.

Now I had the rare opportunity to take it out recently. It was halfway fun, but it's going to take some more work. Mouse turds everywhere. Rear view mirror fell off while I was driving it. Kept wanting to die at return to idle so I had to two-foot it. I've got a new TPS that should hopefully remedy that.

Now for next steps, remember that CFI I mentioned? Well I happened to stumble upon one at a local yard. Again, the guy wanted way too much for it. But for marginally more I could get the whole 5.0 with it. Not such a bad deal then. Another fox gets the 5.0 and I can put the injectors in this one. Have to get the Quarterhorse off the twin turbo GT and put a wideband in this one for the injectors. Then we'll see just what it can do...and how soon I'll need to build that spare shortblock sitting in the garage.
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