DIY Port injection set up

Discussion in 'Mazdaspeed 3/6 Fuel, NOS, Meth, & Water Injection' started by Maisonvi, Jul 11, 2016.

Watchers:
28 users.
  1. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    Finally have my PI system up and running after a few hiccups. Talking with Will at PD tuning (@Captain KR) I mentioned how I somewhat built up my system myself doing it on a bit of a budget, and he said I should post up a list of what I used and how much it cost for people who aren’t going all out. I look at this kit as somewhere between the SP36 kit and a 5/6th port kit.

    I bought a lot of my parts second hand or via deals I was able to find. I will list the prices from Edge as they are the easiest to get. My goal was to be below $2k including the manifold. I came in well under that, and even with full retail pricing the total comes out below that.

    The parts list:
    JMF PI manifold: $979.07 (Current Edge Autosport price)

    DW65C: $149.00 (I used a DW300c, but the DW65c should be plenty)
    EDIT: after lots of headache and trouble shooting I figured out that my DW pump was terrible and having issues. With that said, I dont recommend DW pumps for this application. I will look up alternatives and update at a later point.

    Bosch 60lb/630cc Injectors: $146 (Bosch PN: 0280158298, I bought them off ebay, you can look elsewhere if you want. 48mm EV14 plugs. You can buy adaptors or wire them yourself)

    Split Second Controller: $299 (Emailed Spit Second and asked for the Mazda specific 4 injector controller)

    Fuel Fittings: $161.76 (I grabbed a bunch of Earl’s from summit for pricing. You can use whatever you want, mine was a hodge poge of Fragola and Earl’s fittings. This is not what you have to use, and I recommend specing out what you need yourself, this is just a reference list)

    2x 5/16” to -6AN adaptor (EAR-165056ERL)
    1x Plug w/ O-Ring (EAR-AT581406ERL)
    1x 6an to Straight Cut 6an (EAR-AT985006ERL)
    1x Tee Fitting (EAR-AT926106ERL)
    3x 90 Degree Hose End (EAR-309106ERL)
    1x 45 Degree Hose End (EAR-304606ERL)
    6 FT Hose (EAR-350606ERL)

    Total: 1734.83

    That should be all you need to make yourself a budget PI system.

    Other optional things I added to mine was the Speed Performance wiring hardness for the Split Second controller. I really hate wiring and thought I could have saved money, it was worth it to me for plug and play. Also I added a fuel gauge and adaptor right off the fuel rail so I could see pressure. Not needed but it’s nice.

    Im still in the process of tuning, but with my turbo I think I will max it out with room to spare as far as fueling goes. This set up I believe could also be used with the new Damond Motorsports ST manifold kit I believe. They might have to chime in more on that. @Farhan@DM or @Matt@DM what do you think?

    Let me know if it looks like I missed anything.

     
    Last edited: Sep 25, 2017
    • Like Like x 10
  2. nekret

    nekret Gold Member

    Joined:
    Feb 23, 2016
    Posts:
    566
    Trophy Points:
    43
    Location:
    Vancouver, WA
    Ratings:
    +123 / -0
    That's awesome! did you use the DW300c to replace the OEM pump or are you running both?
     
  3. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    The DW300c (and the DW65c) are both a drop in replacement for the stock pump. The one I ordered even came with a new OEM style sock filter and O-rings. So I didnt have to do any modifying of the basket. Just pulled the old pump out, put the new one in.
     
    • Like Like x 2
  4. nekret

    nekret Gold Member

    Joined:
    Feb 23, 2016
    Posts:
    566
    Trophy Points:
    43
    Location:
    Vancouver, WA
    Ratings:
    +123 / -0
    Sweet! I vaguely remember someone running duel fuel pumps (stock & an aftermarket one for PI) but that sounds like a nightmare for wiring and plumbing. Nicely done sir!

    Sent from my SM-G900V using Tapatalk
     
    nekret, via a mobile device, Jul 11, 2016
    #4
  5. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    Yeah, that's for people going big. 2000cc injectors and what not

    Sent from my SM-G900V using Tapatalk
     
    Maisonvi, via a mobile device, Jul 11, 2016
    #5
  6. etipp98

    etipp98 Greenie N00B Member

    Joined:
    Jul 11, 2016
    Posts:
    4
    Trophy Points:
    3
    Location:
    Parma Ohio
    Ratings:
    +6 / -0
    You should crush your ITFP Regulator as well to get the most out of that pump/ secondaries.
     
  7. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    Care to elaborate more on this? Not sure what you are talking about.
     
  8. CorkSport - Derrick

    CorkSport - Derrick Approved Vendor

    Joined:
    Feb 10, 2016
    Posts:
    410
    Trophy Points:
    93
    Location:
    Vancouver, WA
    Ratings:
    +547 / -0
    You dent the top of the pressure regulator in the tank so it holds a higher line pressure.
     
    • Like Like x 3
  9. GCPhotographers

    GCPhotographers Platinum Member

    Joined:
    Mar 21, 2016
    Posts:
    283
    Trophy Points:
    43
    Location:
    SoCal
    Ratings:
    +115 / -0
    No pictures?
     
    GCPhotographers, via a mobile device, Sep 1, 2016
    #9
  10. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    Not really a ton to show. I was going to do a write up on how to do the in tank pump, but when I was about 1/2 done with my write up, someone posted one that was miles better so I scrapped that.

    I can throw on a pic of my wiring mess that I had going, and the final product. If anyone needs a picture of anything specific, let me know. I guess I just didnt take many. Wiring Mess.jpg 20160505_215350.jpg
     
    • Like Like x 5
  11. AYOUSTIN

    AYOUSTIN Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    435
    Trophy Points:
    93
    Location:
    Lisle IL/Big Rapids MI
    Ratings:
    +571 / -1
    Looks super clean Ken. Just some food for thought, I'd definitely recommend the 300 over the 65. The stock pump is ~230-240lph so the 65 isn't much of an upgrade.

    fuel.gif
     
    Last edited: Sep 6, 2016
    • Like Like x 1
  12. Farhan@DM

    Farhan@DM Approved Vendor

    Joined:
    Feb 18, 2016
    Posts:
    48
    Trophy Points:
    33
    Location:
    Westchester, IL
    Ratings:
    +148 / -0
    Sorry I missed this post. This setup does, and will work with the FoST manifold PI adapter. In fact, the test car is running almost an identical setup, including the in tank fuel pump.

    You need to have the recommended injector fuel pressure delta (usually 40+psi) between the fuel rail and the air in the manifold. I assume Maisonvi will top out ~30-35 psi boost pressure, so you want about 80 psi at the rail to be safe. At 80psi fuel pressure, the stock pump is flowing 200 lbs/hr, or about 125LPH. DW claims 200+LPH on the 65, and 250+ LPH on the 300 at 80 PSI.
     
    • Like Like x 3
  13. AYOUSTIN

    AYOUSTIN Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    435
    Trophy Points:
    93
    Location:
    Lisle IL/Big Rapids MI
    Ratings:
    +571 / -1
    Wow reading comprehension fail on my part. For some reason I thought it was tested at LPH. I retract what I said.
     
  14. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    So Im running into the issue you brought up here. My fuel pressure delta is killing me. Im getting about 50 psi on the rail at WOT, dropping from about 60 at cruise/idle. (video of this can be seen in my build thread)

    So at the 50psi rail pressure I should be around 320 LPH (300 LPH @ 60psi) the issue is my injector delta I think is hurting me as well. It would seem the pump cant keep up and thus the dropping pressure. My injectors are rated at 630cc at 43.5 psi and 740cc at 58psi. According to Enki and rough math puts the injectors at about 476cc at 25 psi (50psi - 25psi of boost). Using his calculations I come out topped out at 477 whp with a 50/50 mix. Which matches pretty well with my 465 VD result topped out on 50/50.

    So maybe to this point, this system isnt the end all be all solution for 500 whp I was hoping for. Unless I can figure out a way to keep fuel pressure up Im going to need to look at doing something different. Im not sure there is a way to adjust the stock regulator other than "crushing" it (which Im not a huge fan of) and if it only gains me 3-4 psi thats not going to be enough. I will say that the stock regulator is supposed to be 60-71 psi, so I am on the low end of that, others may have better luck than me in this regard.

    Granted Im still 100hp over what the stock system can do, and thats nothing to scoff at, but for $1500 I was hoping it was going to give me a bit more.
     
  15. Farhan@DM

    Farhan@DM Approved Vendor

    Joined:
    Feb 18, 2016
    Posts:
    48
    Trophy Points:
    33
    Location:
    Westchester, IL
    Ratings:
    +148 / -0
    You already know it works well above that when working properly. You have a mechanical issue, likely with the pump, possibly with the regulator.

    The regulator is just a spring. Crush spring, increase spring load. Shouldn't hurt anything. You'll need this, anyway, but it will NOT solve your problem if the pump has an issue.
     
    Farhan@DM, via a Nexus device, Nov 4, 2016
    #15
    • Like Like x 2
  16. Bigelow

    Bigelow Gold Member

    Joined:
    Nov 21, 2016
    Posts:
    47
    Trophy Points:
    8
    Location:
    Battleground, washington
    Ratings:
    +7 / -0
    What made you plug the end of the pi rail? I'm ordering my fuel fittings here shortly and was thinking about running my low pressure fuel line from fire wall to passenger side of pi rail then to the hpfp. Do you think this will cause issues? I think this could possibly fix your low rail pressure with the aux fuel due to always having flow. But do you see a problem with hpfp not having enough supply?
     
    Bigelow, via a Samsung mobile device, Mar 6, 2017
    #16
  17. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    That is the method I have moved to now, but Ive added in a boost based regulator as well. I think my issue is the DW pump I have, which maybe if I swapped that out my system wouldn't have the issues its having (since Ive heard of numerous issues with DW pumps). But since Im going to a walbro 450, Ive changed up how Im running the lines as well. This is the new plan, using the stock feed as a return and running larger feed line to the rail and then HPFP.

    15820427_10109528337956174_196394862_n.jpg
     
    • Like Like x 1
  18. xfeejayx

    xfeejayx Greenie Member

    Joined:
    Feb 22, 2016
    Posts:
    49
    Trophy Points:
    18
    Location:
    Chicagoland
    Ratings:
    +48 / -0
    I'm not sure your regulator can work properly that way. Usually they control pressure by opening to dump the excess through the regulator into the return; your drawing would mean the regulator opens to increase/maintain pressure.

    What I'm suggesting is that you go pump>new feed line>hphp>rail>regulator>return. That's the "tried and true" sort of setup. It shouldn't be any more difficult for you since you're already talking about using the stock feed as a return, implying your new regulator is under the hood.
     
  19. Maisonvi

    Maisonvi Silver Member

    Joined:
    Feb 10, 2016
    Posts:
    1,044
    Trophy Points:
    113
    Location:
    South Haven, MI
    Ratings:
    +1,312 / -0
    Yeah, there was a discussion on if this would work or not. Hopefully it's not an issue but if I have to, new lines can be fabbed

    Sent from my SM-G900V using Tapatalk
     
    Maisonvi, via a mobile device, Mar 7, 2017
    #19
  20. Bigelow

    Bigelow Gold Member

    Joined:
    Nov 21, 2016
    Posts:
    47
    Trophy Points:
    8
    Location:
    Battleground, washington
    Ratings:
    +7 / -0
    What was all involved with getting that 450 in stock basket?
     
    Bigelow, via a mobile device, Mar 7, 2017
    #20
Loading...

Share This Page

Users Viewing Thread (Users: 0, Guests: 0)