Another V8 Swap

[DustinS]

@zeal86 I use Fusion 360 to design the parts. Besides the small fender vent, I haven't been able to really use the scans to do anything useful. I am just not experienced enough to do anything with them yet. Really trying though

[DustinS]

Got home and lost most motivation to work on the car as it was windy and kind of cold. Got the fuel lines on, heater hoses installed, worked on radiator hoses a bit, and got the flywheel covers installed:





Also got the test print finished up. This is a little over 50% size. Got the new spool of filament and will most likely start printing the first on tomorrow

[Zer0]

Nice update the ducting test print looks good.

[DustinS]

Weekend was eventful. I spent around 14 hours working on the car Saturday. I was expecting to only be working on it for a couple hours and have it done for Cars and Coffee. Definitely wrong. Got it started to a terrible noise which I thought meant it was all coming back out. That "flywheel" cover on the starter happens to hit the flywheel.... I let that one clearance itself out. No pictures as I was just trying to get it done.

Here is where the issue start. Car had an issue priming (Fuel Pump). As in it primed once the first time I turned the key on. Then wouldn't again for another 20 minutes. Messed with a few grounds to make sure they were connected well. Still no dice. Though if it primed, it would run fine.

Got the car on the ground Sunday, buttoned up a few last things (Mainly a coolant leak at the heater line on the firewall). Went for a test drive and it drove great, Vibration at 2500 rpm is gone. I am pretty sure the vibrations that are there are normal for a v8 with almost solid bushings. Very happy there. Drove it to the car wash, all was well until I tried turning it on the leave... No priming/No Start. No fuel. Spent half an hour trying to get it to do it just once before finding the issue.



Pin on the fuel pump connector heated up and melted the fuel hat. Pin was stuck on the connector. Though the connector didn't show signs of any heat. It's wet with fuel, so I somehow dodged a bullet and the car didn't burn down (though at this point )

Car is sitting in my friends garage waiting for me to figure out the next move. Neither of my 20 amp fuel pump fuses are popped... Hoping my fuel pump didn't somehow die. Though it is a DW300c that is almost 3 years old at this point.

2 options. Drill out the connector and use heavy gauge wires and pot the pass through with epoxy, or go to the radium hanger. $10 mod or $600+ mod haha

[DustinS]

Got to work on the car right after work (and a trip to grab hardware). Pulled the fuel pump assembly and it was hard not to notice the issue:



It was isolated to just this plug, so I assume the connection was poor and caused issues over time. It was completely melted together and I can't get it out at all. So I just cut the wires flush. Put epoxy in the melted hole from the top.

Drilled slightly undersized holes, put some epoxy on a nylon washer, and used stainless m6 screw as a stud. Should be sealed very well, and will hold up to plenty of amps. Shouldn't have any issues with melting things unless I have a very bad problem.



I engraved the "P" into the top the best I could. Then marked "P" and "N" to help from screwing it up next time. Even though it's pretty easy to check before putting it together. Wanted to make it idiot proof.



Quick shot of the new grill blanks I made from 1/8 ABS to get rid of that terrible looking corrugated plastic. Just need to make the side pieces that attach to the radiator to help force air into it. I noticed the fans stay on for a considerable amount longer than with the old full blown radiator and stock fans. We will have to see how well they hold up to summer heat and traffic.



Car was really clean until the storm last night

[jflogerzi]

Originally Posted by DustinS

Got to work on the car right after work (and a trip to grab hardware). Pulled the fuel pump assembly and it was hard not to notice the issue:



It was isolated to just this plug, so I assume the connection was poor and caused issues over time. It was completely melted together and I can't get it out at all. So I just cut the wires flush. Put epoxy in the melted hole from the top.

Drilled slightly undersized holes, put some epoxy on a nylon washer, and used stainless m6 screw as a stud. Should be sealed very well, and will hold up to plenty of amps. Shouldn't have any issues with melting things unless I have a very bad problem.



I engraved the "P" into the top the best I could. Then marked "P" and "N" to help from screwing it up next time. Even though it's pretty easy to check before putting it together. Wanted to make it idiot proof.



Quick shot of the new grill blanks I made from 1/8 ABS to get rid of that terrible looking corrugated plastic. Just need to make the side pieces that attach to the radiator to help force air into it. I noticed the fans stay on for a considerable amount longer than with the old full blown radiator and stock fans. We will have to see how well they hold up to summer heat and traffic.



Car was really clean until the storm last night

Looks really good. We need some videos of how it sounds and drives.

Sent from my ONEPLUS A5010 using Tapatalk

[DustinS]

Originally Posted by jflogerzi

Looks really good. We need some videos of how it sounds and drives.

Sent from my ONEPLUS A5010 using Tapatalk

Definitely going to get some. Terrible Vibration at 2500 rpm is gone, so the car will see a lot of use this season.

[DustinS]

More pictures. Mostly of radiator mounting/hose routing

[Zer0]

I like the radiator, and mounting. Interested to see if it keeps up with your cooling needs.

[alex87f]

Isn't the intake located at a spot where it's only going to get super-hot air? Can you make a duct to bypass the fan and get cool intake air ahead of them?

[DustinS]

Originally Posted by alex87f

Isn't the intake located at a spot where it's only going to get super-hot air? Can you make a duct to bypass the fan and get cool intake air ahead of them?

Yes and no. Plan is make ducting for the radiator to keep the heat from the filter (was the major choice in designing the radiator fan ducting on the last page, but it needs tweaked slightly).



BUT you can actually see the filter behind the badge in this picture:



The small bit of power I lose to hot intake air isn't much of a worry as I make more than enough for the chassis/tires I have currently.

Got this picture yesterday:

[Joesurf79]

This!!! This QD EFI to AN connector!! Is that 3/8"???

[DustinS]

Originally Posted by Joesurf79

This!!! This QD EFI to AN connector!! Is that 3/8"???

Well unfortunately Summit caps the order history, so I can't look on my order list, and I don't have access to my receipts. That being said, I am 80% sure it is 3/8" EFI fitting. So you would be correct.

[Joesurf79]

Originally Posted by DustinS

Well unfortunately Summit caps the order history, so I can't look on my order list, and I don't have access to my receipts. That being said, I am 80% sure it is 3/8" EFI fitting. So you would be correct.

Appreciate it! plumbing in my surge tank this weekend, fingers crossed - this was the last piece of the puzzle...