Couple of pic of my turbo charged, intercooled 2F

[frontrange]

This is a FJ40 turbo conversion project I've been working on for the last few weeks. Today I got done fitting up my stainless exhaust which marks the last of the plumbing - well almost. I still have to fit the battery tray and alternator before I can run the tube between the intercooler outlet and the throttle body, but that's a detail.

So I thought I'd post a couple of pics and show off my work...



That's a Garrett GT2876R turbo. The intake is a mid 70's stock unit I modified for multiport injection with a Ford throttle body and Ford fidle valve next to it.

I moved the radiator back a bit and put a large intercooler in front of it, fits perfect and yes the headlight buckets clear with no problems.



Still need to paint the body and assemble an engine before it's going to be back on the road, but I'm getting there slowly...

 

[J Kimmel]

I'm getting there slowly...

Not once you get it running cool project

 

[rckhound]

That is an awesome project. Nice work.

 

[rover67]

nice what are you planning on running the injection with? megasquirt or something else?

Really cool project.

 

[frontrange]

Megasquirt it will be. I just got done adding a couple of mods to add real time barometric correction, and turbo boost control. Here it is with the case open & attached to a simulator for testing:



The Megasquirt is a very a capable ECU with a lot of nice options. One of the things I really like is they can work with a fuel composition sender to adjust boost and timing based on the amount of alcohol in the fuel. I plan on running E85 whenever I can to take advantage of its 105 octane and run the boost up accordingly.

 

[rover67]

nice, I'm excited to see how it turns out!

 

[frontrange]

Another pic of the turbo that shows the exhaust to turbo detail.



And the intake

 

[frontrange]

Here's how the intercooler tucked in. I was really surprised and pleased at how well this one fit with minimal fuss. I had to move the radiator over a tad to clear the FJ62 steering box anyway, so setting it back about an inch at the same time was no big deal.

 

[PabloCruise]

What a wicked cool project!

Fuel pump?

 

[frontrange]

Good question. As I'm sure you know MFI requires a high pressure pump, and those don't last very long unless they are effectively cooled by being immersed in fuel. So I built this tank with an internal pump pretty much first thing after deciding to fuel inject my 2F.



The coating is Line-X, I thought it would add an extra measure of safety since they use the stuff to help blast proof buildings, plus I like the look...

 

[wesintl]

one of the more interesting projects i've seen in a while. Nice!

 

[frontrange]

Thanks, it's been a classic case of mission creep. I think I've now run out of things to do "while I'm in there". Plus I hope to be able to join you guys in Moab next year if I can, so now I have a completion deadline to work towards.

 

[PabloCruise]

Good question. As I'm sure you know MFI requires a high pressure pump, and those don't last very long unless they are effectively cooled by being immersed in fuel. So I built this tank with an internal pump pretty much first thing after deciding to fuel inject my 2F.



The coating is Line-X, I thought it would add an extra measure of safety since they use the stuff to help blast proof buildings, plus I like the look...

Sweet! Any pics of vent line routing?

 

[frontrange]

Sweet! Any pics of vent line routing?

I'm beginning to think you didn't fall off the turnip truck yesterday when it comes to MFI conversion on vintage auto's

So I pondered the tank venting issue a lot. I originally wanted to put a charcoal tank in there, and run a purge cycle to clear it under the right circumstances. SteveH was kind enough to copy the portion of the factory manual that covered the evap system for his late model FJ40, so I have everything I need to make that work if I have to.

With that said, everyone on the net who's posted anything I've seen on this subject just doesn't sweat this. They all just vent the tank to a small engine filter or the like.

If this ends up creating a fume problem in my garage, I'll do something about it. Until that happens, I'm going to call it a non-problem. I know how to program arduino microcontrollers and have the conditions documented to run the purge cycle at the right time, so doing a OEM type fix if necessary won't be an issue I think.

 

[rover67]

Good call on submersing the fuel pump, it will be much happier than an in line setup.

 

[frontrange]

Good call on submersing the fuel pump, it will be much happier than an in line setup.

It was another "while I'm in there" decision. A friend and I made the tank before moving out to CO in 95. But a few years ago I decided I wanted to Line-X it along with some other parts. So I decided to cut the service port and install the fuel pump first knowing I wanted to go FI down the road.

The manual for the Megasquirt points to a few OEM inline fuel pumps used in early days of fuel injection, and I'd expect those to be reasonably reliable, but the fact that every OEM in this day and age that I know of uses in-tank pumps probably speaks volumes about the merits of going that route.

 

[rover67]

Yeah, external pumps suffer mainly from cavitation and overheating... at least that's been my experience on inline setups. Throw in an inline filter on the upstream side and it makes the cavitation worse since the pump pulls harder. Get a nice hot day when the fuel gets hot... worse again. Now add some elevation.... now add some ethanol... ick. It'll cavitate and you'll be chasing lean issues, the pump will overheat, then finally lean issues will turn into no run issues. Then the no run issues turn into no fun issues.

 

[nakman]

Just awesome, thanks for sharing. Is that a Ford shock tower? You need a nut..

 

[frontrange]

Just awesome, thanks for sharing. Is that a Ford shock tower?

Yes it is

You need a nut..

Thanks for the warning, glad I didn't take it out on the road that way...

 

[PabloCruise]

I'm beginning to think you didn't fall off the turnip truck yesterday when it comes to MFI conversion on vintage auto's

So I pondered the tank venting issue a lot. I originally wanted to put a charcoal tank in there, and run a purge cycle to clear it under the right circumstances. SteveH was kind enough to copy the portion of the factory manual that covered the evap system for his late model FJ40, so I have everything I need to make that work if I have to.

With that said, everyone on the net who's posted anything I've seen on this subject just doesn't sweat this. They all just vent the tank to a small engine filter or the like.

If this ends up creating a fume problem in my garage, I'll do something about it. Until that happens, I'm going to call it a non-problem. I know how to program arduino microcontrollers and have the conditions documented to run the purge cycle at the right time, so doing a OEM type fix if necessary won't be an issue I think.

Ha ha, I try not to fall off the turnip truck, but yes, having lived through a couple of engine swaps, this has my attention.
I worry that instead of creating a fume problem in your garage, it will create a fume problem in the vehicle cabin while driving. I had a vehicle that was not purging the charcoal can properly and man did that end up stinking inside :vomit: Hopefully your approach will work well! Does your setup utilize a return fuel line?