Project Lex (aka: Teh Bean) '92 SC300

[Halon]

Exhaust Fab is still coming along slowly but surely. Probably slower than normal cuz my fab skills aren't too great. Thanks again to Mo for all the welding, and dealing with my shitty fabbing.


Mocking up the muffler

Here you can see it splits to dual 2.5". The one side is all tacked together. The other side is just started.

 

[toyotanos]

Looks like its lining up nicely, but what's with the no uber huge exhaust tips? Good work!

 

[Halon]

Lolz on tips comment You'll notice the muffler is somewhat recessed, which is because I left some room to put tips on at a later date. Surprisingly the tip I want is proving quite hard to find. I'll end up with a 3.5" tip I think. Clean and simple, anything larger might start looking a little too "noticeable" for me.

 

[toyotanos]

Yep, my 4.5" tip is a bit gawdy, but I can't argue about it. The exhaust is ridiculously quiet, which is what I want.

funny thought... think like rim/tire fitment: all you have to do is fill the gap I think sme OEM style ovalized tips would look very clean and sleeperish if that's what you're after.

 

[Bleakvoid]

Eh, it all depends on the bumper. On my widebody, even the giant 5" diesel tip (its the same diameter as the muffler can) doesn't look out of place. 3.5" round tips should fill out those cutouts just perfect, though. Something oval would work wonderfully, too...4" wide, 3" tall, maybe?

 

[Halon]

4" I think is getting a little too big for me. 3" looks decent but doesn't quite fill up the bumper cut-out enough, so really I'm thinking 3.5" is what I want. And I'm not digging the oval stuff.

So with that being said, I just ordered up a pair of these tips 2.5 in x 3.5 out x 8 long

http://www.autoaccessoriesgarage.co...utm_term=Cherry-Bomb-Double-Layer-Exhaust-Tip

 

[Halon]

Well it's taken me several weeks, but FINALLY I got the exhaust 99% complete. All I have left is to grind down some of the less attractive welds, and do some finishing touches on the tips (they are very close, but the passenger side one sticks out a hair more so I need to tweak it). I tried to get some better pics and a video with sound but the humidity here is so ridiculous for the past couple days, my video cameras lense kept fogging up seconds after getting it in the garage. Attached some pics. Overall I'm pretty happy with it because my fab skills are not that great, so it turned out pretty good for someone like me

 

[Halon]

Took it oooot n aboooot to the gas station. Filling up on some delicious 87 Drove pretty good. I really like the exhaust note. It's much quieter than the Talon, so that's great! And I love these Borg Warner turbos, they are super loud and sound awesome! I got to about 5psi and that's about it. Pulled pretty hard but I let off right away. So far so good! I'm super excited!

 

[toyotanos]

Very nice tips, I like the look a lot!

also...87? :nono: needs moar octane! (I tend towards the safe side of things) Do you have active knock monitoring and knock control on the MS board?

 

[Halon]

No knock control at the moment, but I may in the future. I just got cheap 87 as I'm going to be spending most of my time doing normal driving, working on getting a nice steady idle, and mainly staying out of boost as I just make sure everything is working as it should (which will take some self-control lolz). Once I start feeling like the car is running decent enough, I'll switch to premium and then start getting into boost a bit more.

 

[Halon]

Drove it to and from work today Did pretty good besides the battery not wanting to hold a charge...

Pics!

And a little video.
http://www.youtube.com/watch?v=wLIJQM6zv2U

 

[Halon]

Starter has been acting kinda funny. Finally yesterday it wouldn't start at all. Quick trip to Vatozone and she's alive again

Out with the old, in with the new!

Also I got the wideband wired into Megasquirt now (MS3 pin 23). So hopefully I can set that up to start auto-tuning. The AFR's have been all over the place which probably didn't help with the smokey-ness. Hopefully they start to come inline a little better now.

 

[ScSyndrome]

Good to see another SC Megasquirted!

 

[Halon]

Gave the car a complete detail last weekend. Thanks to Blaine Auto Detailing, got a heck of a discount too thanks to Mo. There's still plenty of flaws in the paint that a buffer just can't fix. But they did a decent job considering the condition of the paint. The interior and engine bay looked great as well. Here's a couple pics. Will probably be taking my Envoy there as well and let them go nuts on it too Also this week I'll be starting on the Fuel system.

Same pic, just a couple different camera settings

 

[Halon]

While disassembling to do the injectors and AFPR, I quick did a compression test.

1 - 210
2 - 210
3 - 210
4 - 200
5 - 175
6 - 200

Cyl 5 might be part of the reason we saw so much smoke in that video I posted... But still seems good enough to let er buck for a little while

 

[Halon]

Started on the fuel system. Got the injector clip pigtails soldered in in-place of the stock clips. Then installed the injectors. Decided to install my AEM AFPR since I was right there. I had a spare -6 to M12 x 1.5 fitting laying around. Found the hole where the stock FPR was mounted accepts an M12 tap pretty much perfectly as-is without drilling the hole any larger. So I tapped it and installed the fitting. The AEM AFPR inlet ports are made to screw into a -6AN fitting. So I mounted it right to the fitting on the fuel rail. Nice and simple/clean, I really liked it! Just didn't like the way it pointed. So I tried to turn the fitting a little bit more. Oops, snapped the fitting I was able to extract it so no real harm. I ordered some replacement fittings from Summit that arrived today. So I finished up the install today. I'm pretty happy with how simple of a setup it is.

Next I need to get the car running on the new injectors, and set the base FP with the new AFPR. Then install the dual 255hp pumps, get it half-way dialed in, then take it to Shane at DB Performance to get it tuned on the dyno at around 15psi levels for now.

Anyhow, on to some pics of the injector/AFPR install:


Tinning the pigtails:

All pigtails soldered/heat shrunk in place:

Tapping fuel rail for M5 x 1.5 fitting (if I were to do this again, I would have done 3/8npt)

Fuel rail tapped

Fitting installed. You can see the blue fitting is the M6x1.5 for the Fuel Feed. The silver one is the spare one I had laying around and is being used for the return end

Injectors and fuel rail installed

New set of BCPR7ES plugs

AFPR wasn't in the exact angle I wanted so I tried turning it a little more, Ooops

Easy out to save the day

Purchased a new bunch of fittings from Summit (didn't take pics of it all though). Ended up using the same blue Earls fitting for the return as I had on the feed (I like the oring it comes with).

AEM AFPR installed with Turbosmart gauge. I love the stealth black look

Hard to see, but I simply used a 3/8" male-male barbed fitting to extend the stock rubber return hose to reach the new AFPR

All done

 

[Halon]

Set the Base Fuel Pressure to ~42psi by jumpering B+ and FP on the diagnostic port with the car off.

Using TunerStudio's "Required Fuel" wizard, adjusted the required fuel setting from 10.2 to 3.7 with the new injectors. Car started right up and idled pretty much perfect. I decided to play with TunerStudio's advanced Idle ignition/fuel settings, and I'm really happy with how it's idling right now! Idles so much smoother than my Talon ever did with those 1600's.

Now I just need to drive around and let the Auto-Tune feature do it's thing. Then get those dual pumps installed, then real tune!!

 

[Halon]

Vid of start-up and idle with new injectors.

http://www.youtube.com/watch?v=VntljfdpQ7w

 

[Halon]

Well I got kinda motivated in the last few hours of the night, so one more update

I decided for now, to install a single Walbro 255hp as that really should be all I need for right now since I plan on running fairly low boost for awhile. And it was quick and easy and gets me back on the road, because winter is right around the corner. I'll install the 2nd pump this winter I think.

Anyhow some pics of the install.

I made a newb mistake. I thought the cover in the trunk was the cover plate for the fuel pump. Nope, oops, that's just the fuel float, lolz. Realized the pump is located behind the rear seat, bastards.

Removed the rear seat and got the old pump out.

Was hoping I would get lucky and could use the stock pump electrical connector on the new Walbro, but nope. I cut the stock connector off, and crimped/heat shrunk the new Walbro pigtail on. Used the stock rubber spacer dealy on the bottom of the pump and bam went install was a snap!

Reset the base fuel pressure to 42psi. Now will just spend the next few weeks getting the car running as good as I can before throwing her on the Dyno!!

 

[Halon]

Drove it to work, and drove it around town after work today to let Auto-tune do it's thing. Car was running pretty well I'd say.

So at around 9PM-ish I made a decision

I was down to damn near E on the fuel gauge. She took 15 gallons of the good stuff, and immediately noticed a different on the Wideband! Car drove like hell for the 2 mile trip home.

dded about 25% fuel across the board, and she's running much better now. Will have to drive around a bit though and let it do some more Auto-Tuning.