Another One of Those Single Turbo Conversions

**mauromj** · 04-01-2016 11:12 PM

Well, this is what I have been building lately. I was considering a build thread, but got to preoccupied in the build itself rather than taking pictures. Hoping to order a TTV flywheel within the next couple days so I can get it dropped into the car.

And the car its going into. Oh wait, thats not a b5!

**Whiplash_89** · 04-02-2016 05:35 AM

The turbo looks too small :)

**S4tech2** · 04-02-2016 06:24 AM

Sweet!

**a4kamila6** · 04-02-2016 07:51 AM

Beautiful engine, i cannot wait to see how well the car turns out!

**UkuRiSh** · 04-02-2016 09:01 AM

Nice, subscribe! If was me, I would install tee or Y between fuel rails

**mauromj** · 04-02-2016 10:25 AM

Originally Posted by UkuRiSh

Nice, subscribe! If was me, I would install tee or Y between fuel rails

I still need to figure out the final fueling setup. Clearance is definitely tight in the back, especially after I had to drop the fuel rail to get my injectors to seat properly (didn't want to buy injector hats).

Are you referring to running a y connection to the front? I suppose if I do it that way, I could block the end of one side, and run my FPR on the other. Hmmm.

**mikeb17** · 04-02-2016 11:48 AM

I was wondering when you were going to make a build thread ;)

**mauromj** · 04-02-2016 11:57 AM

Originally Posted by mikeb17

I was wondering when you were going to make a build thread ;)

Meh. They are over-rated. lol

**UkuRiSh** · 04-02-2016 12:02 PM

Originally Posted by mauromj

I still need to figure out the final fueling setup. Clearance is definitely tight in the back, especially after I had to drop the fuel rail to get my injectors to seat properly (didn't want to buy injector hats).

Are you referring to running a y connection to the front? I suppose if I do it that way, I could block the end of one side, and run my FPR on the other. Hmmm.

You Should use for booth " front and rear " Fuel feed -8 AN and split to Y connection with two -6 AN in to the front rail and same way back to FPR. On my S4,A4 fuel line from the thank " feed " was connected to the front rails and back of the fuel rail to FPR, that way your pressure should be equal up to FPR. If you cap rear fuel rail or loop them together then your fuel rail pressure will be different specially between 1st and 3rd cyl. My fuel setup was fine for 700WHP and I used Fuelab FPR for my last build. Also you can loop back of the fuel rails together and use any side of the fuel rail on front to feed fuel and another side back to fpr should work too. Good luck with the build.

**mauromj** · 04-02-2016 12:06 PM

This is what I am thinking for fuel setup now since space is so tight. Thoughts anyone? From a fluids point of view, it should work fine. Will it work alright in practice though?

**mauromj** · 04-12-2016 08:12 PM

Got some new motor mounts in. Motor will be going in the Friday/Saturday

Oh yeah, also got some 034 aluminum sub-frame bushings on order. Should be here in the next couple days.

Front end should be nice and tight. :)

**Monty23** · 04-13-2016 07:17 AM

Originally Posted by mauromj

This is what I am thinking for fuel setup now since space is so tight. Thoughts anyone? From a fluids point of view, it should work fine. Will it work alright in practice though?

No. you need fuel to flow in one side of fuel rails and right out the other side. You can't block off one end of the rail.

**julex** · 04-13-2016 07:23 AM

Originally Posted by Monty23

No. you need fuel to flow in one side of fuel rails and right out the other side. You can't block off one end of the rail.

Well, technically he could but there is one sound reason not too... After assembling everything there will no doubt be some junk and minor debris in fuel lines. Without a flow through design that would take it back to tank, this crap will be forced sooner or later through injectors and clog/damage them. I would also think that fuel evaporating would definitely create vapor lock in last 1 or two injectors without a clear shot through the whole rail....

**mauromj** · 04-13-2016 07:29 AM

Originally Posted by julex

Well, technically he could but there is one sound reason not too... After assembling everything there will no doubt be some junk and minor debris in fuel lines. Without a flow through design that would take it back to tank, this crap will be forced sooner or later through injectors and clog/damage them. I would also think that fuel evaporating would definitely create vapor lock in last 1 or two injectors without a clear shot through the whole rail....

Makes sense. Thanks for the response.

**SpeedWorksAuto** · 04-13-2016 07:44 AM

Wouldn't that setup only have good fuel pressure to one side of the motor?

**NOTORIOUS VR** · 04-13-2016 07:50 AM

Originally Posted by Monty23

No. you need fuel to flow in one side of fuel rails and right out the other side. You can't block off one end of the rail.

No you don't.

That said, the fuel regulator is in the wrong spot in his diagram.

**Monty23** · 04-13-2016 07:52 AM

Originally Posted by julex

Well, technically he could but there is one sound reason not too... After assembling everything there will no doubt be some junk and minor debris in fuel lines. Without a flow through design that would take it back to tank, this crap will be forced sooner or later through injectors and clog/damage them. I would also think that fuel evaporating would definitely create vapor lock in last 1 or two injectors without a clear shot through the whole rail....

Well you could properly setup a returnless fuel system, but the way he drew it is far from correct. And you would need a pump controller to control fuel pressure.

**Monty23** · 04-13-2016 07:54 AM

Originally Posted by NOTORIOUS VR

No you don't.

That said, the fuel regulator is in the wrong spot in his diagram.

Ok you could block off the end of one rail, but not both...

Edit, I guess you could if you had a Tee fitting at each rail and then the regulator down stream of both rails. Wonder what pressures the injectors at the end of the rails would see at high IDCs. This would be nice from a packaging standpoint. The system wouldn't deal with air bubbles very effectively though as bubbles in the rails would have to go through the injectors.

**julex** · 04-13-2016 09:38 AM

^^ Right, I wasn't even thinking about FPR when I said my piece. Obviously our system needs pressurized fuel rails and in the diagram above there would be no pressure on rails...

**incontrol7** · 04-13-2016 10:07 AM

where did you source your stern mounts from?

**NOTORIOUS VR** · 04-13-2016 10:33 AM

Originally Posted by Monty23

Ok you could block off the end of one rail, but not both...

Edit, I guess you could if you had a Tee fitting at each rail and then the regulator down stream of both rails. Wonder what pressures the injectors at the end of the rails would see at high IDCs. This would be nice from a packaging standpoint. The system wouldn't deal with air bubbles very effectively though as bubbles in the rails would have to go through the injectors.

The regulator location needs to change either way. It needs to control both rails not just one like the OP has it designed in his picture.

For this to work, it would be Feed > Regulator > Y-fitting on outlet > line to each rail.

Each rail would be capped at their ends and the return would be coming from the regulator. So it would be the FPR in front of the rails modulating rail pressure.

I haven't personally seen any issues with rail(s) being capped in this way, I wouldn't personally do it that way unless there wasn't a choice though.

**Monty23** · 04-13-2016 11:56 AM

Originally Posted by NOTORIOUS VR

The regulator location needs to change either way. It needs to control both rails not just one like the OP has it designed in his picture.

For this to work, it would be Feed > Regulator > Y-fitting on outlet > line to each rail.

Each rail would be capped at their ends and the return would be coming from the regulator. So it would be the FPR in front of the rails modulating rail pressure.

I haven't personally seen any issues with rail(s) being capped in this way, I wouldn't personally do it that way unless there wasn't a choice though.

This doesn't make sense. How can the return come from the regulator if you have the feed going to the regulator inlet and the regulator outlet going to the dead ended rails? if you put the return between the feed and regulator, the regulator won't see much pressure. If you put the return between the regulator and the rails, the rails won't see much pressure. Unless I'm misunderstanding you.

**mauromj** · 04-13-2016 12:09 PM

All of these responses are confusing the crap out of me. lol.

Shouldn't it not matter where the FPR goes in theory? As long as it see's (and releases excess) pressure wherever it sits, it will function and keep both rails at constant pressure. Other than the issue julex brought up (about debris staying in the rail) wont that setup I initially posted work? Please explain why it would not. I am not understanding fully apparently.

-Matt

**NOTORIOUS VR** · 04-13-2016 12:11 PM

Originally Posted by Monty23

This doesn't make sense. How can the return come from the regulator if you have the feed going to the regulator inlet and the regulator outlet going to the dead ended rails? if you put the return between the feed and regulator, the regulator won't see much pressure. If you put the return between the regulator and the rails, the rails won't see much pressure. Unless I'm misunderstanding you.

Aftermarket regulators can work this way.

Code:

Feed > Regulator > Output
           |
        Return

**mauromj** · 04-13-2016 12:11 PM

Originally Posted by incontrol7

where did you source your stern mounts from?

They came from: http://www.etspec.com/

I contacted the owner directly and he gave me a deal. PM me for more info on this.

**mauromj** · 04-13-2016 12:13 PM

Oh yeah, and the reason I want to block off the back of the rails and run the feed lines into the front is because of space limitations. I have like zero room back there to run fittings and lines. Not sure how you single turbo folks have pulled it off in the past.

**NOTORIOUS VR** · 04-13-2016 12:29 PM

Originally Posted by mauromj

Oh yeah, and the reason I want to block off the back of the rails and run the feed lines into the front is because of space limitations. I have like zero room back there to run fittings and lines. Not sure how you single turbo folks have pulled it off in the past.

You could do a center feed if you wanted even

**aysix** · 04-13-2016 12:45 PM

Originally Posted by mauromj

They came from: http://www.etspec.com/

I contacted the owner directly and he gave me a deal. PM me for more info on this.

lol blake

what sort of deal?

**Monty23** · 04-13-2016 01:01 PM

Originally Posted by mauromj

Oh yeah, and the reason I want to block off the back of the rails and run the feed lines into the front is because of space limitations. I have like zero room back there to run fittings and lines. Not sure how you single turbo folks have pulled it off in the past.

Plenty of space:

**mauromj** · 04-13-2016 04:37 PM

Originally Posted by NOTORIOUS VR

Aftermarket regulators can work this way.

Code:

Feed > Regulator > Output
           |
        Return

Yup, and this is how I have it in the drawing.

**mauromj** · 04-13-2016 04:59 PM

Originally Posted by Monty23

Plenty of space:

What size thread are the IE rails?

**CJ_** · 04-13-2016 05:05 PM

-8 an o-ring port

**mauromj** · 04-13-2016 07:02 PM

Originally Posted by CJ_

-8 an o-ring port

The fitting that comes off the fuel rail is 8an. The other side (that goes in the fuel rail) is smaller than that one, so there is no way its 8an. Must be 6an?.

**Monty23** · 04-13-2016 07:29 PM

Ie rails have -8an o ring ports. I have a -8an oring 90 deg with a -8an to -6an adapter that goes to the -6 hose

**CJ_** · 04-13-2016 08:14 PM

Yeah, I'm running 8an oring to 6an male reducer, 6an elbows with 6an feed and return as well

**mauromj** · 04-13-2016 08:43 PM

Ok. Figured 034 and IE rails were the same size. Mine are definitely smaller than 8an.

**NOTORIOUS VR** · 04-14-2016 05:18 AM

Originally Posted by mauromj

Yup, and this is how I have it in the drawing.

Your drawing is wrong still.

**hibiscusS4** · 04-14-2016 06:22 AM

Originally Posted by Monty23

Plenty of space:

goes single turbo still has .5mm of room to work on motor lmfao

**julex** · 04-14-2016 06:25 AM

In your drawing the FPR would go before Y-split. You'd need two port FPR for this. You'd have the return line coming out from return port on FPR (so normal set up) but the two inbound ports which normally connect to back of rail would be configured differently. One would be input from fuel line, the other would go to Y-Split and to rails. Done. A little awkward but would probably work just fine but make 1000000% sure you purge the lines somehow before you start the car to avoid junk going into injectors.