The last bits of the intake manifold build are to put in ports for the PCV system and install the MAT sensor. Easy, right?
Except to know where I can fit those I need to know where they can't be and where they can't be are the spaces the fuel rail and thermostat housing need to occupy.
Soooooo..... thermostat.. yeah....
The thermostat housing on the Suzy motor sticks out the back of the cylinder head about 5 inches or so. Through the firewall and well into where the fuel tank sat and I hope will be again.
On the intake side of the head is a 1/2" heater port. I want to use that area to run to an external thermostat housing. First thought was to mill that area out and weld in an extension.
But looking at it after I leveled it out I had an idea.
The hole being in the lower left corner of that block was why I couldn't just drill and tap it to -12 or something. But what if I machined that face at a bevel? That would point the threads level in relation to the angle of the motor AND move the hole towards the middle of that space.... in theory at least.
and it worked!
so I cut threads in it.
And then, still not knowing what I am making I turned up a quick base that threads into the new coolant outlet on the head
Patting myself on the back, I started planning some sort of thermostat housing that would mount to the number 4 intake runner and then I looked at the space I had and went dangit, Fuel rail and assorted gubbins goes there too, doesn't it.
So I wrung my hands for a while and then ordered some Bosch 550cc injectors
and I grabbed some more of the same aluminum bar I made the control arms from and drilled a 13" deep hole. It was annoying and I really would have been better off drilling from both ends but for some reason I didn't.
And then some machining happened
and I have a fuel rail. I mounted a WRX regulator to it. I am already dissatisfied with it. I would really prefer one with a barb for OE style quick disconnect fittings. I like using nylon fuel lines
I was able to drill and tap the intake for the MAT sensor. Final step on the rail is the inlet. Still deciding what to do there
So the regulator sits pretty much exactly where I was going to put the thermostat housing. I think that is probably a blessing in disguise as I now realize it would be almost impossible to access once in the car. Current thinking is to turn that base I threaded into the head into a hose barb and figure out where I want to put the new bits under the intake.
As always, more later
