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BRINGING IT ALL TOGETHER.... A's, G's & E's


4 posters

    EFI intake manifold construction

    jdlaugh
    jdlaugh


    Number of posts : 298
    Location : Tulsa, OK
    Registration date : 2013-03-18

    EFI intake manifold construction Empty EFI intake manifold construction

    Post by jdlaugh Fri Sep 07, 2018 2:07 pm

    I decided i really wanted full-blown fuel injection for my '65 E-pup, so I looked at some designs online and tackled making a new EFI intake manifold that would fit inside the doghouse.

    I've already installed and tested a MegaSquirt system using the Ford TFI ignition and distributor from an early 90s F150 4.9. I originally installed to control throttle body injection, but think I will get better performance from multi-port injection.

    Main components of the intake are a flange for a Ford 300/240 that I found on E-bay, some mandrel elbows and sheet metal. I also butchered a 4.9 fuel rail. Here are some pictures of the process and test fit.

    EFI intake manifold construction A_efi_10

    The intake plenum is 3x3x26 inches long it fits under the lid and within the confines of the doghouse. Fuel injectors are 24 pounds per hour Bosch units that should support 200+ hp.

    EFI intake manifold construction B_efi_10

    Okay, I'm weird. The throttle body is pointed straight down and will be fed by a turbo back under the bed next to the transmission. The exhaust manifold is not as close as it appears in the photo, but I do plan to fashion a heat shield for the TB and may wrap the headers.

    I have debated doing without the turbo, and could just as easily route the intake air from behind the front grill, down along the frame rail and in this same way.

    EFI intake manifold construction C_efi_10

    The plenum started out as a flat sheet of 22 gauge metal from Lowes and was formed on a DIY bending brake. The finished plenum has a volume of approximately 234 cubic inches.

    EFI intake manifold construction D_efi_10

    The mandrel elbows are 1.5 inch,16-guage tubing off e-bay. The runners are just over nine inches total in length.

    EFI intake manifold construction E_efi_10

    I'm using a throttle body off a 4.6l Mustang with a 3-inch bore.

    EFI intake manifold construction F_efi_10

    Fuel injector bungs were another e-bay purchase. Trimmed to fit close to the manifold and all at the same angle.

    EFI intake manifold construction G_braz10

    I butchered a stock 4.9l fuel rail and brazed together the rail and pieces of steel fuel line to create the custom fuel rail. I've never used this particular technique for fuel lines, but I've built bicycles using brazing and expect it to be plenty strong.

    EFI intake manifold construction G_fuel10

    The finished fuel rail. I debated on using the original Ford fuel rail couplings, but went with flare fittings instead.

    EFI intake manifold construction H_thro10

    My original throttle cable will route over the top of the engine and will need a short adapter to reach the throttle arm.
    jrdunn96
    jrdunn96


    Number of posts : 691
    Location : Cashion, OK
    Age : 62
    Registration date : 2016-01-01

    EFI intake manifold construction Empty Re: EFI intake manifold construction

    Post by jrdunn96 Fri Sep 07, 2018 5:00 pm

    Wow JD! I'm speechless and that don't happen much.
    Jim
    Seth G
    Seth G
    Vintage-Vans Listings Manager
    Vintage-Vans Listings Manager


    Number of posts : 2086
    Location : Anacortes, WA
    Age : 50
    Registration date : 2013-04-24

    EFI intake manifold construction Empty Re: EFI intake manifold construction

    Post by Seth G Sat Sep 08, 2018 10:41 am

    Thanks for the update JD. Looking forward to seeing more!
    jdlaugh
    jdlaugh


    Number of posts : 298
    Location : Tulsa, OK
    Registration date : 2013-03-18

    EFI intake manifold construction Empty Re: EFI intake manifold construction

    Post by jdlaugh Thu Mar 28, 2019 4:40 pm

    Finally got the truck running with the multi-port fuel injection system. Here's a short video:

    Seth G
    Seth G
    Vintage-Vans Listings Manager
    Vintage-Vans Listings Manager


    Number of posts : 2086
    Location : Anacortes, WA
    Age : 50
    Registration date : 2013-04-24

    EFI intake manifold construction Empty Re: EFI intake manifold construction

    Post by Seth G Fri Mar 29, 2019 7:59 am

    it's purring like a kitten. You've got to be pretty happy with that.

    Are you worried the heat from the manifolds is going to kill the throttle body?
    jdlaugh
    jdlaugh


    Number of posts : 298
    Location : Tulsa, OK
    Registration date : 2013-03-18

    EFI intake manifold construction Empty Re: EFI intake manifold construction

    Post by jdlaugh Fri Mar 29, 2019 9:33 am

    I'm a little concerned about the plastic flex downpipe melting. Not so much when driving, as air flow will keep it cool enough, but when heat builds up in the doghouse after shutting down. I'm planning to wrap it with a heat-reflective tape, which should help.

    The only part of the throttle body that might be a concern is the throttle position sensor. I think it's far enough away from the exhaust to be okay. The pictures and video are a little deceptive and make it appear the TB is closer to the rear manifold than it really is.

    Only time will tell....


    Trainmaster
    Trainmaster


    Number of posts : 36
    Location : Rockaway Beach, New York
    Registration date : 2018-06-04

    EFI intake manifold construction Empty Re: EFI intake manifold construction

    Post by Trainmaster Fri Apr 26, 2019 4:17 pm

    This is just too cool!

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