Custom Fuel Rail

[code109]

so I ordered a turbo for my Hillman hunter project car which should be here Friday or just after... was going to make a link to my build thread but don't know how so just go through my profile to get to it if you're interested haha

anyway ive been looking at getting the fuel system on the engine bay side of things uprated to match the new fuel system in the boot and also cope with a turbo

I started looking at aftermarket fuel rails, mainly the awesome looking flyin Miata purple ones, but nearly had a heart attack when I saw the price!!!

then I remembered I'm an engineer.... ha so I thought why not make one from scratch! got a block of Ali and came up with a rough design taking measurements from the standard rail

so pics of the progress so far, will keep up to date as I get on with it

the standard rail and what the new one will be made from;

this is a simple drawing of my design... I'm sure it will change as I go on to accommodate for things I've forgotten haha;

my plan is to drill all the holes and pipe lines and stuff while its a nice square block, then profile it afterwards,

so first thing is to bore a hole through the entire length;

the hole drilled without any mishaps thank Christ!   9.5 mm hole 13" long haha;

there's light at the end of the tunnel!!!

that's as far as I've got so far but should get more done tomorrow after work so i'll keep this up to date

[Good Scrap]

My goodness, drilling a hole through 13" is a task in itself, dd you part drill form each end or find a mega long drill from somewhere?

I'm surprised it didn't wander, at least the most risky operation is out of the way,

I'll be watching this progress as it'll be an interesting project for you.

Brian

[code109]

yeah I approached it from both sides, just went extremely steady, feed rate of 20mm/min haa... although the trueness of the two holes meeting up is testimony to the machines in my work! but yeah everything you said is exactly why I did it first, even before I squared the ends up

[theheap]

We see a few made this way come into our workshop. They all go for the real ones in the end. Still have these laying about the place.

[code109]

do you know of any issues that arise? or anything I should bare in mind?

[code109]

okay got more done this evening, couldn't do anything yesterday due to an absence from work with suspected food poisoning haaa

anywayyyyyy I squared up the ends to the correct length and have all the holes drilled now, just profiling next...

the holes for the injectors, i'll insert stainless "cups" to sit the injectors in;

and the holes for mounting, and the fuel in pipes and return / pressure regulator take off;

and the injector side again;

I'm hoping to pop in for a bit tomorrow morning so should have it completed and ready to fit some stainless injector cups (have to turn them still)

will keep updated for anyone interested

[sowen]

Really nice stuff, keep it up! Looking forward to the finished article, inspirational stuff

[v8]

Nice job so far

[theheap]

Just don'take the holes/lines too small. Well work ok no problems

[v8ian]

Holes for the fuel don't need to be massive, 6mm is ample I ran a engine with 330 hp with 8 injectors on a 6mm id pipe,

[code109]

Cheers guys

Started roughing out the profile;


Then finished the profile and tried the regulator take off in place;


Started turning down stainless m16 bolts for the injector cups;


Thread locked them in place ready to be machined;


Also got a bit artsy and put a simple design on the top;



All that's left is to machine the cups and plumb it in

[sowen]

Much tool envy

That is very impressive stuff, love it

[code109]

Finished the injector cups this evening









Have fitting coming this week to plumb it in

[MrSpeedy]

Very nice work

[aseriesandy]

Lovely work. Out of interest if the place you work at was to price this up as they would any other job, time, materials, set up and design with a modest production run how do you think it would compare to the flyin Miata purple ones you first looked at?

[forkliftfred]

Cool. Keep the updates coming.

[code109]

Thanks everyone much appreciated

Feb 25, 2015 11:59:17 GMT aseriesandy said:

Lovely work. Out of interest if the place you work at was to price this up as they would any other job, time, materials, set up and design with a modest production run how do you think it would compare to the flyin Miata purple ones you first looked at?

I honestly wouldn't like to say, I mean I got the block of Ali for free from an old mate at a different engineering company but that wouldn't be cheap

Then it took me about 8 hours in all which is a days work, so you'd be looking at around 300 just for the labouring costs... When the flyin miata ones are 200 - 300 with the plumbing fittings and stuff so...... :/

[aseriesandy]

Now you can tell people it is priceless! Keep up the great work.