731 replies to this topic

[ENGINR]

the stock dowty washers are a must have shayne

I've been lucky not having any leaks sofar, but I'll get a pair and next time I do an oil change will put them in.

[Evo-00x]

Theyre cheap as Shayne. 2 bolts and 2 washers including delivery should be under $20 all up from Amayama.
I got mine through STM and took pics of the part numbers for us lol

[bazeng]

transfer case is overkill for your little car.
Sell it to me.

[Evo-00x]

lol Baz. A wise man once said its better to over engineer than to break shit and walk home lol.

[Evo-00x]

Bit of an update:

Thanks to Mikey and Frankie for coming over during the long weekend to help weld up and fit the new bend on the turbo to intercooler pipe

I cranked the engine over with Benno today and the new alternator is providing 14.4v at idle which is plenty of charge for the new battery. When the high beams and fans were put on full, with stereo and gauges operational, it was effecting the idle a lot (due to not having the car tuned yet with the recent mods) and the idle was dropping to around 600-700rpm. When holding the pedal to around 1100rpm where I anticipate the idle will be set, the voltage was still over 14v. That's a great sign that the new alternator, thicker wiring and earthing kit are doing their job properly

On another note Ive gone back to using Castrol Edge 10w-60 oil as originally used since building the engine (tried Penrite HPR 10w-50 there a couple of times but I noticed a difference). All I'm going to say is that in my engine at least, the Castrol quietens the engine more, appears to allow it to rev quicker and provides a lower cold start oil pressure of 60-62psi. (Penrite was 70psi when I had the engine running in May with the ported housing). Even though both oils are 10w rated, the Edge somehow flows better cold, plus the 60 rating will provide better protection for the oil pump and engine at high oil temps, especially when the engine is spinning at 8,000rpm+

Overall it feels great to kick it over and hear it running again. Health wise Im feeling much better and the best Ive felt for over 2 years too. Its great to get some energy back!

Now I just need to book it in for a tune and enjoy it for a while, provided the oem 4th gear holds lol

PS: I haven't fitted Rob Barac's Shep Racing transfer case and beefed up driveshaft to the car yet because Im waiting til Shayne and I get our dog gear upgrades done before I build the spare box.
I cant believe I already have plans to change shit and its not even back on the road yet

[ENGINR]

Great to hear Rob

[evopwr]

Awesome build Rob. Your car is a testament and inspiration - showing that anything's possible whatever the circumstances!

Love how you put in so much TLC & research into everything you do, with no shortcuts! Respect.

[Evo-00x]

Thanks guys. I know both of you boys have put a lot of TLC and effort into your own cars too.
Here's some respect back because I love reading up on what you boys get up to in your own builds.

[DOUGMO]

high five man!

[Evo-00x]

Revisiting something I started to look at over the last Xmas holidays and am determined to sort out within the next couple of weeks.

Back in January I changed my under body oem steel fuel line to 3/8" (-6AN / 10mm) alloy tubing, and using that oem steel fuel line now as my fuel return line from the FPR.

All that was left to do was to replace the crimped metal pipe coming out of the oem EVO fuel pump cradle to a 6AN fitting on the outside and a 3/8" barb on the inside to connect to a Walbro fuel pump. This would make the fuel system match the Walbro 400Lhp barb outlet all the way to the fuel rail without any restriction in tubing size. 

 

So off I went to ENZED this afternoon and purchased steel fitting # 30382-6-6 which has a male 3/8" JIC (6AN) fitting on one side and a 3/8" barb on the other side.

Grabbed a spare EVO fuel pump cradle and drilled out the OEM steel tube (yeah, the ones that have a habit of bending and crushing or snapping off! ).

The little buggar of a fitting fits perfectly where its supposed to and the internal barb stops where the 255Lph Walbro starts (Note: 255Lph Walbro has a smaller diameter outlet than the 3/8" newer 400Lph Walbros have).

 

In the attached pics you can see the fitting through the cradle lid. On the side of the cradle I used black texta to mark where the 255Lph Walbro is normally mounted. With the barb in position the Walbro sits in exactly the same place [like a glove - fist pump]. A connector hose will fit between the two. Now I just have to weld the fitting in and paint the welds in special fuel tank paint, then get myself a Walbro 400Lph fuel pump to mount into the cradle    

 

Will show the finished result when its done.

  

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[Evo-00x]

Frankie came over this arvo and welded it in. Then I cleaned it up and temporarily sprayed it with galvanised coating for now [edit - had to soak it and clean it back off as its not ethanol fuel resistant paint dammit - worth a shot] so have to check what paints are fuel and ethanol resistant like a smaller version of the KBS fuel tank paint I used inside the fuel tank [see post further down for KBS paint used].

 

Its a fiddly and tight weld job and you need to take your time and not get it too hot. Do a little then walk away and let it cool down, then come back and so on. Too much heat will warp the cradle lid. Alternatively use a couple g-clamps to clamp it down on a flat surface then weld it.The plastic plug next to where we were welding slightly melted but doesn't adversely effect it at all. It has no electronics inside it, rather its just a solid plastic lump of a thing with pins in it to connect the big oem white plug outside the cradle to the 2 x small plugs inside for the fuel pump and fuel level float. 

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Edited by Evo-00x, 25 April 2019 - 01:24 PM.

[Evo-00x]

Well... went to install the Walbro 416 E85 version today and am a bit surprised with how its been marketed as I suspect many people would have upgraded their fuel line diameter to 3/8" or 6AN to suit its advertised barb size.

Fair enough it flows what it does which is the most important thing, but the actual 3/8" barb fitting on it is actually just the barb OD, not the ID of the fuel outlet. 

The outlet looks virtually the same size as the smaller Walbro 255Lph pump = very small. 

When you really compare the ID against a 6AN fitting (3/8" fitting), the Walbro is dwarfed in size (see pic).

In actual fact its smaller than the OEM fuel line diameter anyway lol.

This means you could run an E85 Walbro fuel pump using the OEM fuel lines if you wanted to - but larger diameter fuel lines will help the pump flow easier and not work as hard.

 

Anyway, to make the Walbro fit I had to cut the barbed end off the Walbro (flushed it with WD40 to get rid of plastic shavings) and use a 3/8" hose to connect it to the 6AN barb fitting I had welded inside the fuel cradle.  

Next I noticed that the body was long and the oem lower bracket wouldn't bolt on using the same rubber mount as the Walbro 255. I thought about elongating the hole for the oem bracket to lower it and risk the fuel pump bottoming out at the bottom of the tank, but thought it would be much easier just to slice the lower rubber mount in half to fit it in - done lol.

 

As the Walbro E85 version has its own thick power wires coming out of the unit, you will need to use them to connect to the white plug in the cradle.
I know a lot of guys will just solder the Walbro's wires onto the internal oem wires but these pumps do draw a lot of current (not necessarily volts) and the paperwork recommended to use 14-16 gauge wiring for it. Anything the same thickness at least as what comes with the Walbro fuel pump or thicker is recommended. So do yourself a favour and remove the connectors from the oem white plug, remove the oem wires from the connectors, then install the Walbro 416's wires into the connectors with solder and heat shrink, then put the connectors into the white plug again.
 

These Walbros use a larger fuel filter that connects backwards to the oem filter but Im not sure if it will fit inside the tank.

Will update with the actual installation in the next couple of days.

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Edited by EVO-00X, 03 November 2013 - 03:40 PM.

[DOUGMO]

nice work rob, at least the flow improvement is through the same sized outlet which isn't a bad thing.

It should the job until you decide to really lean on it

[Evo-00x]

Oh yeah that'll go down well lol.

The little Walbro 255 was doing fine at 26psi, 98 pump and 880cc injectors through OEM hard fuel lines. I know others have ran 30psi with them and OEM lines - totally under-rated pumps they are.

Now with the bigger Walbro and 3/8" hard fuel lines its E85 ready at least - whenever that happens  (probably when my brother beats me in a race lol)

 

Install continued...

 

Taped up the threads and used aluminium foil to block holes in the cradle, then treated it with KBS-Coatings fuel tank paint. I bought their small 'system sample kit' and asked for the small 250ml 'gold' sample version of the fuel tank sealer in the kit instead of the 'rust seal' that is shown in the pic below. Cost was only $36 for the sample kit. I only used about 50ml overall so have some left over to use for my brothers car and other things  The finished paint job is not going to win any show and shine awards, but it does what its supposed to do and protects the welds and cradle from corrosion forever. Let it sit outside to cure for a couple days before installing it back into a fuel tank that already has fuel in it. 

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Edited by EVO-00X, 09 November 2013 - 06:28 PM.

[Evo-00x]

And to finish off the new Walbro 416 E85 install:

 

* I removed the thin oem fuel pump power wires and pins from the white plug in the cradle, then installed the Walbro's own thicker black and red wires into the pins with solder and heat shrink before putting them back into the plug.
* The fuel pump assembly fitment must have been on a slight angle because we had to make a slight dent in the bottom of Mik's spare Evo fuel tank to clear the bracket. I had to do the same to mine.
* I also found out that the Walbro 416's big fuel filter, as pictured in my previous post above, couldn't be used because it faces the opposite way to oem and hits the side wall of the fuel tank. I then put another filter on similar in size to that of the Walbro 255, however that filter stuck out too much and bottomed out on the base of the fuel tank so you couldn't get the cradle to sit all the way down   So off that one came and on went my old fuel filter that came with the Walbro 255's installation kit number 400-847. Only has about 5,000kms on it so its all good lol.

Then hall-e-fukin-lu-jah, it fit So after several attempts in and out of the fuel tank, the surrounding chassis black paint turned into a blackish-brown gooey molasses that got all over my hands and everywhere. Gotta clean that shit up now.

Anyway, I turned the key to accessories and you can only just barely hear the fuel pump now. If the old Walbro 255 sound level on a scale of 1-10 was a 10, then the new Walbro 416 has a maximum sound level of 2. Theres no loud whine when priming the injectors on accessories either, just a very slight ssssssssssshhhhhhhhhhhhhh sound

 

Oh, and if anybody ever damages or is missing their oem white plug to power the fuel pump, you can find the same white plug in Walbro installation kit 400-791 which is the kit made for a Subaru WRX, Liberty, Impreza etc.  You wont find this replacement plug in Mitsubishi ASA as it only comes as part of the entire fuel pump setup. I even went to Jaycar and Dick Smiths beforehand but had no luck finding one like it. Luckily I found a spare. See 3rd pic of the Walbro installation kits.

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Edited by Evo-00x, 25 April 2019 - 01:22 PM.

[evopwr]

Rob's at it again. Quality and Quantity!

[leadfoot]

mmm make me want your old one now who am i kidding i'm gonna need a 400l unit eflex baby

[jack be nimble]

Get 2 pumps k. One for idle/cruise and both for play. No need for a huge fuel reg and how many ecu outputs do you get?

[Evo-00x]

Why go through the clutter and expense of having 2 pumps and an external surge tank setup if you can get away with one quiet hi-flow internal pump on a street car? 

Kyle's got the right idea with his proposed mods = Haltech Platinum 1000 ECU with eflex fuel sensor and one of these Walbro E85 fuel pumps 

[DOUGMO]

Why go through the clutter and expense of having 2 pumps and an external surge tank setup if you can get away with one quiet hi-flow internal pump on a street car? 

Kyle's got the right idea with his proposed mods = Haltech Platinum 1000 ECU with eflex fuel sensor and one of these Walbro E85 fuel pumps 

because once you finally wind that GTX right up on e85 you will run out of pump? lol