I love this car, what kinda power do you think she’ll have?
Im hoping it will do like 275/300 on 13-15psi initially. I think it will make MAYBEE 425/450ish on 30psi, if I ever tune that high. We’ll see.
I know with my old cam, exhaust, turbo, intake, 93 oct, etc it did this (ugh, 6 years ago):
Dan
Almost done with the engine harness wiring. (I may have finished, but I had to replace the crank pos sensor in the GTI first, meh)
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coil harness is done
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the main harness simply needs the plug for the IAC. Its due friday.
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injector harness just needs a backshell and the firewall connector attached
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firewall plate is almost drilled for the connectors. It still needs holes for the heater core plumbing
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wiper motor rewired to its own connector on the firewall plate. And all other wiring related to the hvac removed
Dan
coming along very nicely :tup:
Come on man… You are ridiculously awesome!
This is my favorite build
Fuck yeah.
:tup:
Finally had a chance to make up the plenum end cap. This was my first attempt at forming something like this. Its not quite as round as I would have liked, but its def better than a flat plate. I will probably get it fit, smoothed and weled on tuesday nite.
Dan
Spent almost 5 hours on the stupid harnes tonight. I had to pull the old inside harness out, strip a bunch of wires off of the main MS harness, remove a firewall connector etc. Pretty much I re-pinned and re-wired the whole thing. I have 3 more wires to connect to the MS but I didnt have the schematic handy. Anyway, getting SOO close to being done with wiring.
Oh, added a shot of the injector harness I finished up last week.
The two white molex connectors near the main MS connector are for the injectors and coils as I added two exra boards inside the MS box to drive them. I made new end plates for the MS box to allow for room for them. I didnt get any pics of this yet, hopefully tomorrow.
Dan
fuck this build is so kickass!
ALOT of progress tonight.
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smoothed, finished fitting and welded the plenum end cap
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cut, ported and welded the throttle body flange
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made the cold side charge pipe, including the BOV bung (that I had to cut off the old piping
All the intake needs now is some minor porting, sanding, and fuel rail straps made up and welded on.
Dan
That looks so clean. Now finish this thing and lets roll.
heaterz
so clean ***
Its been a pretty busy week so far.
Primed and painted the firewall braces.
Shortened the fuel rail return hose to the FPR
Re-installed the fuel pressure gauge sender (I still need a hole plug for the FPR gauge port that is unused)
Finished the cold side charge pipe – cut out the hole for the BOV (I always cut and port them after welding) and beaded the ends.
Installed the BOV and the vaccum line (complete with a nice Oettiker clamp)
Removed, welded shut, and ground smooth a notch in the valve cover – previously there for TB clearance on the old setup
Also cleaned up the welds on the valve cover, repainted it and drilled holes for the press in studs (to mount the coils assembly onto)
Before
After
Finished up the Megasquirt mods. Added a peak and hold driver board for the injectors and a coil driver board inside the top cover. To make more room for the boards and two new connectors for Spark and Fuel I extended the sides and ends of the case. Also added functionality for boost control, IAC drive, and launch/flat shift control.
Painted and installed the firewall blockoff / wire connector bulkhead panel. I used some foam gasket tape around the edges so it can be removed easily and still seal.
Re-routed the wiper motor wires to the new bulkhead connector
Finished removing the leftover HVAC blower wiring
Installed the main Megasquirt engine harness and the coil and injector harnesses.
Re-routed the boost gauge tube to the new bulkhead area. I still need to install the bulkhead feed-thru fitting.
I think that is it for this week so far. I’m sure I forgot something. I shouldnt skip an update.
Dan
Starting to come together… Today I did the following:
machined the fuel rail for the hold down straps
made the fuel rail straps and welded them to the intake flange
welded the AN bungs to the fuel rail
everything seems to fit nicely
pressed the 1/4-20 studs into the valve cover
mounted the rubber stand offs and the coils to the valve cover
Installed the firewall braces
Mounted the boost gauge bulkhead fitting to the firewall plate.
Im really getting down to just some final details.
Dan
I love this project and the detail that is put into it!
wait, power steering? did you plan on getting old when you started the build? 
Funny you should say that. Friday a pulley (to use as an idler in place of the ps pump) and a spare rack to gut and make manual showed up.
Stay tuned for that soon.
Dan
Love it.
Great job man.
:tup: Great Progress!