69 F100 - Junkyard Turbo Engine - Video

[speedbug78]

I understand the cost factor. Converting to efi doesn't have to be expensive, but "expensive" is a sliding scale. I was hoping to keep this project under $500 since I had most of the pieces for it already laying around from other projects. Don't know that I'm going to make it though. At the end I'm hoping to do a cost chart of all the little things I had to buy just for information so others could see all the pieces they might not be considering in their budget project plans.

However, if the oppertunity comes up I'd encourage you to do it. If you haven't done one before, it really it a rewarding and interesting project, if you have then I'm sure you know what I'm talking about.

[killakobra]

The other thing is that i don't really like the stock setup and from what i've heard it's limited in adjustment. I also hate to ditch my $600 carb and intake that aren't that old.

[guhfluh]

The progress and work done looks great! I love different stuff that doesn't follow the norm, and love turbos. I have a turbo, Megasquirt Neon and have pondered what I would/could use off of it on a bump.

I do feel compelled to warn of uneven cylinder distribution with the throttle body placement, so be careful pushing it too close to the limit because of that. The original/stock location was much better for even distribution purposes.

[speedbug78]

Thanks for the compliments! I've been working on the wiring this weekend, but we've been doing a lot of family stuff so I haven't made lots of progress. Mostly weeding out the stock harness.
About the intake. I would totally agree with you if this were a carb intake or a draw-through setup, but given the size of the plenum vs. the size of the runners I really didn't think there would be much issue. I suppose I could pull the intake and flow test the ports on my bench, just to see. This setup is pretty temporary anyway, I've much bigger plans for the final version.

[guhfluh]

Large plenum size does help, though the issue is when each cyl gets the same amount of fuel delivered from each injector, but different amounts of air. As long as you keep it in mind and aren't trying to tune on the very edge, I'm sure you will be just fine. I don't think it's your plan to eek every last HP out of this setup, but just wanted to make you aware. I have the same "issue" on my car, and I can tell from the plug readings after a run how each cyl is doing, and don't have the luxury of individual cyl widebands and/or EGT probes, but I am pushing my setup close to the limits.

I look forward to the updates! Everything looks good so far! I want to see some vids when it's finished:)

[speedbug78]

Ok, time for more pictures!

Installed fuse box (man this pic really shows the dirt well)

Mounted_Fusebox.JPG

Feeding the injector harness through the intake manifold:

Installing_Injector_Harness.JPG

My old megasquirt, that will be running all this for a bit, not much exciting here:

Megasquirt1.JPG

[speedbug78]

Been working on this as time permits, and finally got it running today (not driving or anything). The wiring is mostly done, there's no cooling system, no driveshaft, no gas pedal... One step at a time Anyway, after working out a couple of typical wiring bugs, I still only had intermittent spark. Finding out that it was the Megasquirt ignition input putting too much load on the PIP signal from the TFI took a while. After swapping polarity on the ignition circuit it fired right up! I'll try to get more pics soon.

[speedbug78]

Ok, managed to calibrate the temp sensors today, install the wastegate and hook up power steering lines. Made a short vid of it running this time so you can see. Its pig rich, I haven't done any tuning save getting it to idle, it doesn't have a throttle position sensor hooked up yet, and since I can rev it you know its rich.

Disclaimer - while fairly short the vid is still 20MB, so it takes a minute to get.
http://www.wiricksgarage.com/public_pic ... Statup.AVI

[averagef250]

Great work! This is a really cool project!

Might be time well spent to carefully re-torque the headbolts one by one if you haven't touched them.

What's your HMC built with? I need to upgrade the memory on my old Mori-seiki and have thought about dumping Fanuc for EMC, but it's probably above my head and I can't afford to have it down for long.

[speedbug78]

I hesitate to call it a horizontal machining center, but its a 1981 Summit 3UH universal mill, that I got for $500 (bevel gears in the knee were stripped). I removed all of the factory power feed and added geared servos with belt drives. I converted a stick welder over for the servo power supply and am using gecko drives on the servos. The books say I've got $4800 into it including tooling and rigging to get it in the shop. It runs on EMC and I use CamBam for generating the machining files.

[averagef250]

That's a beast! A 50 taper horizontal that size is pretty serious! Can't beat $4800 on the floor making parts. Pay for that in a week on the right job.

Sorry to get off topic, just cool to meet people who build their own CNC machines and turbo 300 sixes.

[speedbug78]

NP, you're not waaayyy off, its still related to my project pretty much Anyway, I don't get up that way much, but if you're ever out to the coast look me up, we'll talk CNC mills and old for trucks a while

[averagef250]

I have family in Newport/Toledo. I'll have to get in touch next time I'm out that way.

[speedbug78]

Update of progress over the last few days.

I made a mount for the megasquirt, it goes right behind where the choke cable was (since its not needed now), and barely fits between the winshield wiper motor and the steering column support. I have plans to eventually make a fake choke knob with a built in USB port that accesses the megasquirt to tune it.

Megasquirt_Mount.resized.JPG

I also shortened the driveshaft, not much exciting there. Its a 2 piece unit and I shortened the section between the transmission and carrier bearing.

short driveshaft.resized.JPG

I am changing the alternator over to the driver's side so that I don't need the huge passenger side accessory bracket at all. This means re-routing the belt, which means the water pump needs to be standard rotation and have a ribbed pulley instead of a smooth one. Thankfully the old style water pump is the correct rotation and I happened to have a ribbed pulley of similar diameter off of an 85 ranger 2.3L. To make it all fit I needed to custom shorten a radiator fan spacer to give the correct offset. These are straight veined water pumps so I could probably turn the stock one either way, but the old style one has the correct bolt pattern on its flange anyway.

Water_pump_spacer.resized.JPG

[speedbug78]

The other thing I did recently was weld up the turbo downpipe. I still need to attach a pipe for the wastegate dump, add an O2 bung, and fab a support strap so its not all hanging off the turbo. It took quite a while to get it to fit right, not a lot of room for the 3.5" pipe. I made it out of a used exhaust system from a 6.0 powerstroke that the owner had upgraded. I ordered some heat shielding for the heater hoses and intake this morning, hopefully I can get the cooling system in soon.

Turbo_Downpipe.resized.JPG

Turbo_downpipe1.resized.JPG

Turbo_downpipe3.resized.JPG