Installing  the Electromotive EFI

Now that I have finished fabricating the intake and exhaust manifolds, I can put everything together on the engine and see if it all works. I pulled the cylinder head off during this process to have new valve guides installed since the machine shop that I used before R'n'R did not think it was necessary. Unfortunately, the guides were so worn that they destroyed the valve stems and I had to get new valves put in as well. 

Here's a shot of the finished and assembled head
This is the turbo bumpstick
Here's the chamber, valves unshrouded and polished. The head was cc'd and all chambers have the same volume, yielding a final static compression ratio (with head gasket) of 8.34 to 1.
One of the things I needed was a way to control the turbocharger boost pressure without spending a ton of cash.  I bought a used Turbonetics Delta-gate waste gate on ebay and then borrowed a Hallman Boost controller to see how it worked.  It is very simple and I decided to make my own version out of AN fittings.  The benefits are twofold:  the boost controller is smaller and mounts to the wastegate, and it is much less expensive.  Here's the parts:
The boost controller works by having a spring hold a ball bearing against a seat, and when the boost pressure lifts the ball off the seat, pressurized air actuates the wastegate.  So, the first thing to do is get a ball bearing and spring that will fit into the 1/8" NPT Tee, then cut a seat into a  -3 to 1/8 NPT AN fitting
 The spring pressure needs to be adjustable to regulate the amount of boost that you want, so an adjuster screw needs to be made.  I used another -3 to 18" NPT AN fitting, drilled it out and tapped it. 
The adjuster screw would slip through the spring without a small nail-head.  Here's the parts: spring, nail-head, drilled, tapped and cut -3 to 1/8" NPT fitting with adjuster screw and locknut.
These parts with the spring/nail-head assembly make up the whole boost control.  A very small hole needs to be drilled in the body of the 1/8" NPT Tee to release pressure from the wastegate after the boost pressure has been reduced.  If this hole was not present, the boost controller would hold pressure due to the one-way action of the ball and spring and this would keep the wastegate open.
Here's the boost controller installed on the wastegate. It threads right into the port and does not have to be affixed to a firewall and plumbed to the wastegate like the Hallman unit.
The intake was painted a dove gray, the only color paint I had at the time, and then bolted to the engine with a stock intake gasket.  That's a throttle body from a Nissan 300zx with integral throttle position sensor.
This shows the intake and wire connector for the TPS hanging from the throttle body.  The AN fitting on the valve cover is a breather, it goes to the block and then dumps into the exhaust.
Another view of the intake. 
Some of the plumbing for the turbo and EFI has been mocked up here.
Here's a trial fit of the exhaust manifold, turbo, wastegate and exhaust pipe. The hole in the exhaust pipe is for the oxygen sensor.  I had to make the plate that bolts to the turbocharger outlet and weld the reducer to it, have it surfaced by R'n'R machine and then weld the 3" U-bend to it.

Electromotive Tec-II installation:

   Part 2     Part 3    Part 4

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