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> Injector Upgrade, new parts for fuel injection
McMark
post Apr 12 2018, 11:42 AM
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I've been working on upgrading the components of my custom fuel injection setup. One of the upgrades I've had in the works for awhile was adapting the newest Bosch injectors. These have an improved spray pattern, are high-impedance, and are available in a variety of spray volumes. And they're TINY!

But like any of this stuff, you can't just bolt them on. I decided to make some fancy adapters that would look mostly original. This was one of my first projects to help teach myself Fusion360 CAD modeling.

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Got a couple 3D prints from some of our members, which illustrated a few issues with my design. A few changes were made and I pulled the trigger on an initial run of 20 pieces (5 engines).

Just received these parts back from anodizing and did a final test fit. Everything looks perfect. So it's time to install this and my upgraded AAR on my 1.7 Turbo and see how these new additions help things.

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McMark
post Apr 16 2018, 09:30 AM
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QUOTE(saigon71 @ Apr 12 2018, 02:16 PM) *
Will the upgraded AAR be available as a group buy at some point? (IMG:style_emoticons/default/biggrin.gif)
Yup. As soon as I make sure it works. I'm also pondering some possibilities that would allow my AAR to be installed as a standalone part -- making it applicable to D-Jet and L-Jet cars.

QUOTE(Mueller @ Apr 12 2018, 02:26 PM) *
Looks good. Are those injectors reasonably priced?
I buy mine from DeatshWerks at $260 for 4. But these injectors are on TONS of new cars. So the pick-n-pull available should be HUGE.

QUOTE(Philip W. @ Apr 12 2018, 02:31 PM) *
also , are the connectors plug and play or is modification of the stock FI connector from the harness required?
Adapter plugs could be made available pretty easily.

QUOTE(Jeff Bowlsby @ Apr 15 2018, 05:33 PM) *
I see this new bracket is not indexed to the tine on the manifold. What keeps the injector bracket from rotating around its bolt and moving from side to side?
Nothing, I suppose. I'm not sure why they would be moving around. These will use the stock fuel rails as well, so that should provide some additional rigidity to guard against that concern. If I do another run I'll look into adding these tabs. I didn't add them initially because I was concerned about machining costs.

QUOTE(Dave_Darling @ Apr 15 2018, 11:37 PM) *
Is there any reasonable way to have the electrical connector point the same way as the stock injectors?
Nope. (IMG:style_emoticons/default/sad.gif) It does rotate freely, so you can put them left/right/down or anywhere in between.

QUOTE(barefoot @ Apr 16 2018, 07:07 AM) *
Nicely done, for your future runs, please add some big fillets between the "sheet metal" part and the cylindrical part, also at the nipple to larger diameter corner, since these are direct metal moulded parts
I'd love to hear more about what you mean. These are CNC machined from aluminum, but you said "direct metal moulded parts" so I thought maybe you meant DLMS/3D-metal-printing. I understand that adding fillets would add strength, but it doesn't seem relevant to this part (no strength necessary). If you're seeing something I'm not, let me know.

QUOTE(brownaar @ Apr 16 2018, 10:03 AM) *
Very nice. My only concern is have you added another potential leak point in the system where the injector mates with the bracket?
Sure. It's an additional potential leak point, but there's not much to be done about this. New injectors are ALL rail mount, so in order to upgrade I had to accept this fact. But it's a potential leak that present in every car that uses a rail-mount injector, which is pretty much every car produced in the last 10+ years. So I'm not doing anything unusual here. Those cars don't have leak problems, so as long as my parts are machined right they shouldn't have a lea problem either.
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Posts in this topic
McMark   Injector Upgrade   Apr 12 2018, 11:42 AM
pete000   Nice work ! OEM Bosch injectors are getting ha...   Apr 12 2018, 11:46 AM
saigon71   Looks great Mark! Please continue to keep us ...   Apr 12 2018, 12:16 PM
Philip W.   Looks great Mark! Please continue to keep us...   Apr 12 2018, 12:31 PM
Mueller   Looks good. Are those injectors reasonably priced?...   Apr 12 2018, 12:26 PM
rdauenhauer   I like it!   Apr 12 2018, 01:30 PM
Jeff Bowlsby   Nice to have an option. I see this new bracket is...   Apr 15 2018, 03:33 PM
rick 918-S   Want   Apr 15 2018, 03:38 PM
Dave_Darling   Is there any reasonable way to have the electrical...   Apr 15 2018, 09:37 PM
barefoot   Nicely done, for your future runs, please add some...   Apr 16 2018, 05:07 AM
brownaar   Very nice. My only concern is have you added anoth...   Apr 16 2018, 08:03 AM
McMark   Will the upgraded AAR be available as a group buy ...   Apr 16 2018, 09:30 AM
Jeff Bowlsby   Nothing, I suppose. I'm not sure why they wou...   Apr 16 2018, 10:25 AM
McMark   Nothing, I suppose. I'm not sure why they wo...   Apr 16 2018, 11:43 AM
Jeff Bowlsby   The chart indicates a 300 kPA test pressure for al...   Apr 16 2018, 12:18 PM
barefoot   I'd love to hear more about what you mean. ...   Apr 16 2018, 01:55 PM
McMark   I'd love to hear more about what you mean. ...   Apr 16 2018, 02:20 PM
McMark   I think I need to order some 90-degree elbows...   Apr 16 2018, 12:04 PM
Dave_Darling   I think I need to order some 90-degree elbows... ...   Apr 16 2018, 12:23 PM
McMark   I think I need to order some 90-degree elbows...Or...   Apr 16 2018, 02:19 PM
Dave_Darling   The problem there is that the 1.7 an 2.0 runners h...   Apr 16 2018, 07:20 PM
porsche913b_sp   Nice :trophy: when are you taking orders :D   Apr 19 2018, 06:41 PM
jcd914   Why not build a fuel rail with proper openings for...   Apr 19 2018, 09:08 PM
rdauenhauer   :idea:   Apr 19 2018, 09:40 PM
John Jentz   :idea: Will the engine go back in with those rai...   Apr 24 2018, 08:04 AM
jcd914   Yes I was thinking of something like that. But I ...   Apr 19 2018, 09:48 PM
edwin   Have you changed the lower orings on the injectors...   Apr 23 2018, 08:17 AM
McMark   Why not build a fuel rail with proper openings for...   Apr 23 2018, 12:04 PM
Mikey914   I always remove my fuel rails (at least now), as i...   Apr 24 2018, 09:19 AM
McMark   :agree: Mike's got it. Pulling the injectors ...   Apr 24 2018, 09:37 AM


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