nathans VY Calais - 'Calais 2.0'

Sorry about the lack of updates, project has really taken it's toll on me lately. But, onwards and upwards.

New front bar has had the split plastic welded and all cracks etc filled and in primer ready for paint.



New manifolds, crossover, wastegate and dump pipe.









As pub said positioning has changed slightly, so some work needed there. Pubs also working on the surge tank, so I'm pretty keen to see that too

 

cheers guys, not sure if anyone noticed in that top photo but have made the fuel rail hoses and mounted the fuel reg off the back of the rail - also sneaky fuel pressure gauge. Have run all the silicone hoses and wiring through to eboost2 in the cabin.

waiting on a couple of fittings to finish off the fuel & oil feed lines then that will be the engine bay all plumbed up. finished the oil return line too.

PTFE = Pure suffering & death, an absolute prick to work with. It's pretty hard to get the length right the first time and it's got bugger all flex in it so it has to be pretty much perfect length.

Needless to say I had to remove the fittings and re-cut a few times. Thank god i'm using pushlock for the surge tank, ptfe down there would be a nightmare.

 

Yeah too right. I do have a sort of deadline, C4C in tassie have already booked the spirit to take the car over for it. But plenty of time still.

Hoping to get it into the exhaust shop to have the dump pipe merged with the exhaust this week fingers crossed..

 

The mrs tells me fittings have arrived so should be able to plumb up the fuel feed line tonight!

 

Fuel rails plumbed

 

Fair mission, lots of grinding and finally got these bastards to fit.

Still need to clean them up a touch and fit the coil packs underneath - fingers crossed the dump pipe still clears, looks like it should.

 

Surge tank coming along nicely thanks Pub247

 

Cheers man

These covers actually have mounting points underneath so you don't use the stock coil brackets at all. It's just a case of unbolting the coils from the stock brackets and bolting them onto the covers.

I have to do that tomorrow night so will take some pics when I do.

 

Coil packs mounted to covers



Elite engineering 2nd gen catch can arrived, it's damn sexy too.

 

I got the E2 can direct from elite engineering: Elite Engineering's 2nd Generation Catch Can - E2 - Elite Engineering

No they definitely still need to be emptied, it's plumbed through but that only circulates the air and removes oil and other contaminants. The e2 only comes in black, but you'd only need e2 if you're running boost, otherwise just go the original elite engineering can.

 

good progress today, pub247 worked his magic on the cooler piping and compressor housing once more. very happy with how it's come up.





What's left to do:

- Wastegate arrives back tomorrow from turbosmart with the ports rotated, after that can fit dump pipe, gate and manifold properly, plug in leads and wastegate silicone hoses
- Tighten clamps on cooler piping, position horns out of the way and refit front bar
- Get car towed to exhaust shop for exhaust merge & cat welded in
- Order remainder of fittings to plumb of surge tank
- Stick a 3/8 bung somewhere in front of the turbo for catch can vent
- Mount surge tank
- Plumb surge tank
- Wire up pumps and relays
- Test fuel system, adjust fuel regulator and check for leaks
- Terminate oil feed line [waiting on fitting to arrive]
- TUNE

 

So I have a bit of dillema, currently as you've seen I have two bosch 044s. I'll need a fair few fittings to get these working.

My feed line is only 3/8 so I'm a bit worried that running two pumps all the time will be a bit much for the line and heat the fuel. 1 pump is adequate for this setup, I can put my fuel filter in the other pump bracket and that'll work well and be a lot simpler.

Down the track I want to look at getting another surge tank made with a submerged, quieter pump as the 044s will be quite loud.

Something along the lines of this one: Multi-Pump Fuel Surge Tank

But yes, my main dillema is which path to go down with the 044s - originally I'd hoped to have the second pump switched on by eboost2 but it seems most tuners are turning their nose up at that idea. The other option is having pumps run all the time which presents with the heat issue.

Thoughts?