custom fuel rails

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beercandrifter
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custom fuel rails

Post by beercandrifter » Tue Mar 27, 2012 5:14 pm

thought i would show some progress of my first small batch of 14mm dohc fuel rails. Sorry for the glare on some of the pics, got dark enough for the camera to toss on the flash. shiney aluminum doesnt like the flash.

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working out the minumum length i can get the fuel rails while not colliding the an fitting threads on the end with the fuel injector holes, was able to shave off about an inch and a half from the rail I made.

ordered some custom extruded angle aluminum for the brackets since I dont have a brake here to make my own.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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supakat
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Post by supakat » Tue Mar 27, 2012 7:40 pm

Sounds good. That garage looks familiar. LOL
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eazye2000
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Post by eazye2000 » Tue Mar 27, 2012 9:15 pm

Sweet! Glad you got around to doing this. Should be able to keep them competitively priced.
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beercandrifter
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Post by beercandrifter » Wed Mar 28, 2012 5:01 am

yeah I happy that I finally was able to go pick up the tools to do this in the garage, makes it much easier

have another thing that I noticed on my rail I would like to try and remedy with future rails. My injector connectors are a tight squeeze to get on once the rail is bolted on the car, may have to adjust the depth of the injector holes to give me about 1mm more clearance for the injector clips or offset the injector holes a little to accomidate for that. Would prefer the offset on the holes if I could get away with it.

and man, i love machining stuff. has to be one of the most rewarding things I have done in my life, its nice just seeing a final product that I can hold in my hands.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by supakat » Wed Mar 28, 2012 5:11 am

I know what you mean regarding the clips. I ran into this issue as well because I went too deep into the rail and when I over tighten the rail, it is impossible to remove/install clips. I thought about notching out or grinding away some material. It really is not an issue for me cause it only happens when I over tighten which then cuts an o-ring anyways.
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13.1 @ 114 - 2.3 60ft - 8/2012
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Post by beercandrifter » Wed Mar 28, 2012 5:15 am

i guess there is one bonus to having them secured by the fuel rail, dont have to use the stupid metal retainer clips =)

man someone really should find out what size oring will work on the delphi injectors to fit in stock intake manifold, that is still bugging me
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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turbonola
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Post by turbonola » Wed Mar 28, 2012 2:00 pm

looks good man, whats pricing on these?
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Post by slidewayzagain » Wed Mar 28, 2012 4:46 pm

price curios also...
either way good work
may your rods stay oiled and your nuts tight

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Post by beercandrifter » Thu Mar 29, 2012 3:22 am

price will be 100$ shipped
includes:
shipping
a sexy 14mm fuel rail
6AN male /6AN male straight o-ring fittings for inlet/outlet
angle mounting brackets
2x 1/4"-20 self locking stainless steel buttonhead(allen) bolts - for mounting brackets to rail
angle bracket mounting hardware (designed for lengths of delphi injectors)
4x washers for replacing the plastic spacers
and the best part, its made in the USA.

if users are utilizing other injectors besides the deplhis (different height), I can leave the mounting hole to the fuel rail on the brackets undrilled to save the end user from having to fabricate brackets from scratch. .
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by supakat » Thu Mar 29, 2012 5:50 am

Sweet. I paid $65 for my rail but had to modify to accept the delphi's. If this option was available about 2 years ago, I would have scooped one up.
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13.1 @ 114 - 2.3 60ft - 8/2012
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Post by beercandrifter » Thu Mar 29, 2012 5:57 am

also, right now there is a 2 week leadtime until I build up my stock here. as soon as everything arrives I can have them made and shipped within 2-3 days.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by beercandrifter » Thu Mar 29, 2012 5:11 pm

well, had my 1/4-20 tap shear off in one of the rails I was making. kinda mad about that. was taking my time lubing it up and all.

did some tuning on my drill, getting some better passes now when making the fuel injector ports.

putting in an order for 10 rails worth of stock and looks like I will be ordering a higher quality tap from msc, another tap handle and will probably pick up a tap from ace hardware like the first to finish the one rail I have here.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by erich » Thu Mar 29, 2012 9:47 pm

You should get a reamer for the final injector port sizing, it makes much cleaner holes.

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Post by beercandrifter » Fri Mar 30, 2012 5:26 am

erich wrote:You should get a reamer for the final injector port sizing, it makes much cleaner holes.
I use a port reamer and the holes come out with a beautiful fillet around the edge. the pictures just are not very good, I will take some new ones.

had to put a fillet on the lip of the injector ports so injector orings dont shear when you pop them in
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by beercandrifter » Thu Apr 05, 2012 7:34 am

so it seems the delphi injectors will require the stock intake manifold to be bored out to .530-.535" per diy's spec sheet now.
that equates to a 17/32" (.53125") drill bit.

that is if you dont want to use rtv and be lazy.


have stock for 10 rails coming in this afternoon. will start machining tonight.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by erich » Fri Apr 06, 2012 4:23 pm

If you take the small o-rings from the stock injectors and put them on the Delphi injectors they fit fine in the manifold ports. At least, that's what I did.
Always remember to lube the o-rings! If you don't, they will probably tear and leak.

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Post by turbonola » Tue Apr 10, 2012 4:41 am

erich wrote:If you take the small o-rings from the stock injectors and put them on the Delphi injectors they fit fine in the manifold ports. At least, that's what I did.
Always remember to lube the o-rings! If you don't, they will probably tear and leak.
did the same thing, no problems here
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11.65@118 1.64 60ft

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Post by beercandrifter » Tue Apr 10, 2012 5:16 am

I have stock for 10 rails to be assembled by this weekend.

have bracket mats coming in tonight
have new rail bolts, washer spacers and manifold bolts here already
have boxes coming in thursday
have the stock for the fuel rail here already

cleared the weekend to get all of these made and ready to ship.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by trevor2086 » Fri Apr 13, 2012 4:30 pm

4x washers for replacing the plastic spacers



Hey man nice work. I'm interested in your rail one question I've had bad experiences with top feed because the 4 o-rings that go on the intake manifold don't seal properly. Do you use just stock or ones or make your own? Thanks

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Post by beercandrifter » Sat Apr 14, 2012 7:02 am

trevor2086 wrote:4x washers for replacing the plastic spacers



Hey man nice work. I'm interested in your rail one question I've had bad experiences with top feed because the 4 o-rings that go on the intake manifold don't seal properly. Do you use just stock or ones or make your own? Thanks
the orings for the injectors? new injectors should come with orings, however, people were saying they had success using the stock orings on aftermarket injectors. you can buy those at most autoparts stores. The delphi orings do not fit on the stock intake manifold, i posted the drill bit size you need to bore out the manifold to if you want to use the thicker delphi orings or you can utilize orings from the stock injectors in the stock intake manifold.



update on the rails. will have 10 ready to ship by monday. will post them in the f/s section when they are all finished with pics etc.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by trevor2086 » Sat Apr 14, 2012 10:48 am

I think I was a little misleading this is what I'm talking about.
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Post by beercandrifter » Sun Apr 15, 2012 4:24 am

http://www.mcmaster.com/#cadinlnord/92320a542/=h458nb
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was what I originally looked at, but they would also be 2.25$ a piece + shipping driving up the cost of the rails. the washers cost me 3 cents a piece.

you can reuse the plastic spacers if you still have them and they work fine, mine were just broken.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by TanManS14 » Sun Apr 15, 2012 1:09 pm

Just picked up one of the RMR rail tools as well. Such a great piece of tooling!
It's always broken.

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Post by beercandrifter » Sun Apr 15, 2012 1:10 pm

going to try and find a source for spacers instead of washers, while they work, its a nuisance to deal with them when installing. spacers will come with the second set of rails

i made some modifications from the test rails I made:
Adjusted the fuel injector ports to allow the fuel injector clips to come off without binding on the rail
Adjusted the length of the fuel rail to be the bare minimum needed to fit the AN fittings which allows for room to route the stock wire harness and fuel lines

Heres pics and the first batch done.
BeercanV1 rails come with the following:
14 mm Fuel Rail tapped for 6AN fuel fittings and 1/4-20 mounting holes
4 M10 washers (in case you dont have your original spacers)
2 M10 Bolts (in case you dont have your original fuel rail bolts)
2 1/4-20 stainless alan button head screws with nylon coating (self locking, vibration resistant)
2 6AN straight male o-ring fittings
2 Angle Mounting Brackets
install instructions
Best part. It is made in the USA

DISCLAIMER* THESE ARE FOR OFF ROAD USE ONLY



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91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by beercandrifter » Mon Jun 18, 2012 5:26 am

well have been getting some feedback on the rails
just a few things to double check before sending them out and only 1 thing to clean up

consensus was the brackets need to be cleaned up some, need to pick up some deburring tools for that

should switch to spacers instead of washers. considering just ordering a batch of the stock spacers

just need to test the pitch of the an threads on the rails I have before letting them out the door and build a jig for consistant taps

overall, pleased with the feedback so far. thanks guys


im still happy i can keep the price down on these for you guys. really hate spending tons of money on parts when one can build something equivalent or better for less.
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by airman » Mon Jun 18, 2012 8:08 am

For spacers you might be able to find a good vendor for small extrusions that you could buy by the foot and just slice them down to the thickness you need.
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Post by beercandrifter » Mon Jun 18, 2012 8:18 am

airman wrote:For spacers you might be able to find a good vendor for small extrusions that you could buy by the foot and just slice them down to the thickness you need.
very true, it wouldnt be too much of a problem since I bought a band saw to make the brackets
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by beercandrifter » Mon Jul 23, 2012 4:34 pm

so any ideas for making better looking brackets?

currently using angle aluminum because it is rigid enough to hold down the rail and is a light piece and isnt super expensive. I cut the angle aluminum on a band saw then file down the edges, drill out the two mounting holes on the drill press and chamfer the holes with a larger bit since the thin aluminum likes to burr really bad when drilling through it.

seems the aluminum likes to chunk/scratch really easy, ending up not looking the best cosmetically even though they work. had comments from a few people on that. cosmetics do have a decent part in it for some people

if i went with like solid square aluminum and machine the brackets, the price goes through the roof (like 30$ to 130$ a stick). have tried looking for L brackets in home depot/lowes/ace hardware for everything from fasterners to door/cabinet brackets to looking in automotive stores for something that would catch my eye, to hours searching on mcmastercarr. havent found a suitable replacement that is comprable cost and strength wise

need to keep in mind, my shop consists of a drill press, bandsaw, a cordless drill, a set of files and the horridly expensive set of bits for the fuel rails
91 240sx Hatch: HomeBrwd
25psi hx35/8.8:1/264^2 cams/95lb injectors/Megasquirt 2/ka24de build **RIP**
T56/4.8 LSx/LS9 Cam/60lb injectors/comp 918 springs/Megasquirt 3/all custom wiring

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Post by Walperstyle » Fri Aug 10, 2012 9:31 pm

just round the edges a little.

(installing mine tonite btw, hence why I'm browsing here)
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Post by Walperstyle » Tue Aug 14, 2012 4:54 am

Have you had anyone complain with leaks due to angle? My latest video update in my build thread shows a slight angle, but it seems to be fairly snug. Should I put a washer between the L bracket and rail to build a little more angle?
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