LS1 Intake Manifolds

[TransAmDan]

Order now shipped from summit. They say delivery will be tomorrow, I reckon it will be more like Monday.

Got my old intake manifold on yesterday, checked for leaks run through car up to temp. All good, the engine is notorious for air bubbles in the system. So I think another warm up and squeezing pipes are needed then good for a test drive.

 

[TransAmDan]

Injectors and fuel rails getting close. Nice customs fee.
Items were aound £800, so it seems about right. Paid it nice and quick, so wont be holding up delivery.

 

[TransAmDan]

When the parcel left summit I got a message around 11.30pm Wednesday to say it's shipped and had the tracking number. Scheduled for delivery Friday. Thinking there is no way it could get here for Friday.(Today) Well it's in Alton ready for delivery today.
That is blooming fast.

 

[saleen 192]

It's a shame uk delivery can't as good

 

[TransAmDan]

It's a shame uk delivery can't as good

Yes, like ordering stuff on eBay that says its UK based, then come from China a month later. Even if you do find a true UK like the Air filters I ordered, it was 24 hours delivery, but they have 5 working days handling. So basically a week before you receive the order.

 

[TransAmDan]

arrived al;ready.

 

[saleen 192]

You got sticker for tool box then

 

[TransAmDan]

Well, the struggle still goes on.
The intake made by FAST. Fuel railes made by FAST, and made for LS2 injectors. Insert LS2 injectors and I can slide the injector up and down. I'm not running with that. The bracket is causing the fuel rail to sit too high.

Fixing fitted, and same as their instructions. Yet I can see the o-ring of the injector.

Bottom of the injector is around 13 mm from the end of the hole. The injectors have a 5 degree andle, so this should be fine.

Measuring from seal to seal, it is the correct length for a LS2 injector, which is what we want

Contacted FAST, they asked me to measure the injector length, and I sent them photos.
Lets see where this goes.

The bracked are L shaped with 2 holes, not quite 90 degrees, more like 80. I could whip up sometihng 3D printed, but its quite a critical part. So may just buy a block of aluminum and drills holes and thread them.

 

[saleen 192]

Fast. Need to sort this for you weather they send you another kit or refund or fuel rail. You shouldn't have to modify it. Fuel system needs to be right with that pressure running through it other wise could have big issues and safety conserns.

 

[TransAmDan]

Fast. Need to sort this for you weather they send you another kit or refund or fuel rail. You shouldn't have to modify it. Fuel system needs to be right with that pressure running through it other wise could have big issues and safety conserns.

Yep true. I did buy from summit. As it's an issue between two FAST components I went direct to them. I wasn't happy with the movement in that injector. The rails should be holding them down. I can't be the only one with an issue. The may have alternative fixings.

 

[TransAmDan]

Injector converters have arrived. My wiring loom has a LS1 type connector on the end. Which dosn't plug into LS2 fuel injectors., Ordered a set of these adapters.

They just plug onto the top of the injector, so I can use my original wiring.

 

[TransAmDan]

3D printed a part to secure the fuel rail at the correct height. As the oringinaly bracked made the fuel rail sit 5mm to high.

Original bracket cant really be modified for the hole to sit 5mm lower as there needs to be a nut on the back to secure it.

My old fuel rails has blocks of aluminum from F.A.S.T, it seems they have made it a little cheaper now with a bent bit of punched sheet.

So using the old idea, where one hole is tapped and the other is a through hole I wanted to prove the height. Fits perfect, feels very nice and strong.

I'm not happy keeping this as plastic, even the PA6-CF Carbon fiber option, its holds the fuel rail on, if for some reason it breaks apart over time the fuel will end up on the exhaust. It may last for ever, but I'm not taking that chance. Planning to get these CNC machined in Aluminum.

 

[renchero]

yours is a much neater looking bracket

 

[chris68coupe]

I would go for CNC metal over plastic, reduce the risk factor - Better option.

 

[TransAmDan]

I would go for CNC metal over plastic, reduce the risk factor - Better option.

Yeah, totally agree. I used to use ADS precision, or Goddard Engineering on Aston road, both gone. I have emailed Cobra Precision Engineering also on Aston road, not used them before. If they can't do it I have a few others to try on the Waterberry drive estate.

 

[renchero]

there was a small machine shop just over the road from me .that's gone too

 

[TransAmDan]

Intake off.

Getting new one prepped. Fuel injectors fitted using thr o-rings supplied. All fitting well, I still may consider the aluminium rail mounts at a later date.

Pipes added. They not taped on, the tape is to hold the bolts up so they do t catch the heads, can't fits bolts after as not enough height under the windscreen. So tape is a good method.

Trouble is the water pump touches under the intake. Probably only 1mm to shave off. Others had this issue too.

Staring to look nice. Coming together well.

Car show on Saturday. Got a few evening to sort it.

 

[TransAmDan]

New in take on. Most connections are together.

Time to start adding the air box.

Looking great, really happy with this. Holda the radiator in nicely. The yellow part is the final part. White is my original test piece. Need to shift the 4 inch hole to the right by around 11mm. I'll print out another draft price to check adjustment, temperature and maf hole.

Not tried starting the car yet, need to put in the new ECU program as these new injectors deliver more fuel. It's on the computer, just need to zap it in.

 

[saleen 192]

Be like a super. Model soon with all that plastic lol.

 

[TransAmDan]

A few times I have had the question, does the new larger intake and throttle body produce more power? Without a before and after dyno it is hard to tell.
We can base it on a sensor in the intake manifold. It measures the intake manifold air pressur (MAP), its done in kPa.

When the engine isn't running its 100kPa. This is just the airpressure we live in, 14.5psi

When the engine is running the cylinders are pulling a vacuum. The ideal pressure on the intake is the same pressure as when its not running at all. This means the cylinders are being fed all the air they need and dosn't pull a vacuum as enough air is present for that not to happen.

The 3 inch intake running 70mpg, foot to the floor. We get 96kPa (around 13.9psi), so pretty good, but its not quite 100kPa.

This is the new intake, 4 inch throttle body, 3D printed ram air air box, and large k&n filters. Not getting 99.0kPa, this meands we are supply more air to the cylinders, more air = more power, how much I do not know. 99kPa is around 14.4psi. So effectivly a 0.5psi increase. Not quite turbo pressures, but a good bolt on gain.

Is the ram air air box making a difference? Well going full throttle at a lower speed would prove that. 2nd gear, still seeing 99.0kPa.
From calculations it was only around 0.1psi at very high speeds. Possibly 120+ MPH we would see the pressure increase in the box to bereadable on the MAP sensor. Would need to find an air strip for that one.