Alright, FINALLY got this all fixed and working. Yay me.

The leak turned out to be on the bottom of the surge tank, one of the allen screws that, like I thought, was not tight. Smacking myself for not checking those before install. Oh well...

I added and changed some things, here is the final fueling setup:

ID1000cc injectors
OEM fuel rail
OEM FPR
OEM fuel pump in fuel tank (I did NOT drill out the siphon return port)
Radium surge tank
Walbro 450 E85 pump in surge tank
Easy Performance fuel pump controller (MAP voltage from 50psi pressure sensor in engine bay)
3/8" feed line from firewall hard line to fuel rail
JEGs 3/8" hose barb inlet/outlet SS billet fuel filter in feed line
150psi fuel pressure sensor in feed line, after billet fuel filter, before fuel rail. (connected to Zeitronix for gauge viewing on Multigauge and datalogging)
Radium fuel pressure gauge on surge tank return outlet to OEM fuel pump assembly.

At idle and cruise, the car is running at 34-35psi fuel pressure: http://datazap.me/u/razorlab/initial...22&zoom=79-674

Also to note, fuel pressure at the surge tank outlet to the return line to the OEM tank is 20psi at idle. I'm assuming that is okay?

I'm still dialing in the initial/full voltage settings on the fuel pump controller, but I did a couple WOT pulls and the fuel pressure at WOT hits a peak of 78psi (at 27psi boost):http://datazap.me/u/razorlab/initial...6-7&solo=2-6-7

The final setup (for now):

 

Not quite so simple now, but needed to be addressed.

Fuel pressure at the rail should always be "base pressure (observed at idle with FPR vacuum source disconnected)" + "vacuum/boost".

 

Okay, just now set the base pressure via fuel pump controller voltage with hose off:

43-44psi

and with hose on:

37-38psi

 

Sounds about right for pressure at idle with vacuum hose attached. You should be seeing -6 psi vacuum at idle in EvoScan.

 

Nice Gains man!

 

Love your approach and what you've done with this. Always enjoy reading your posts.

 

Razorlab quick question. Are you intentionally tapering boost after 5500rpm or is it doing that because the setup is tapped out? Thanks

 

he has stock turbo, it gives up around 5500 rpm and boost falls off as the turbine housing/wheel choke out.

 

So I finally got all the stuff back in the car, seat cushions back in and have been driving the car for the last four days.

Even with the seat cushions back in (SSL leather ones too), there is absolutely no mistaking that you have a fuel pump in a metal cylinder behind the back seats...

The hum is very audible. You hear it more so when you are driving around town, and especially while sitting at lights. On the highway I don't really hear it, even with the windows up since the Evo has so much road noise anyway. So that is good, because I would kill myself if I had to listen to that hum for long distances.

This is at low voltage too, I cannot even imagine it at high voltage. The good news is you can't hear the pump ramp up in voltages much because the car starts making more noise at that point too.

 

What if you wrap the surge tank in a few layers of dynamat?

 

So I continue to do some fine tuning with the surge tank now fully operational. One thing I am finding is that if I do a normal 3rd gear pull from a low RPM, like doing a full single gear WOT sweep, my AFR is great and solid at peak boost (11.8-12.1)

However, if I do a stab of the throttle or a fast transition to WOT at different RPM, like more real-world usage of the car, the AFR goes super rich 10.1-9.9 and you can feel the car bog.

It never did this before the surge tank. I'm thinking it has something to do with the fuel pump controller. Is this something I just need to try and tune out? Do I need to start touching the enrichment tables now?

 

Can you log rail pressure or pressure somewhere along the fuel supply side? How long to the rich AFRs and bog last?

 

Yes, I have a pressure sensor that is loggable on the feed line right before the rail. I haven't been able to log that or AFR lately because I had to redo my logging laptop. However I have in-cabin gauges for both.

I can log now, it's just about finding the time.

The enrichment and bog is right at peak boost.

 

Okay, did some logging today. For some reason Evoscan refuses to log ZTX User2 now, even though it's logging ZTX Boost and AFR just fine, so I had to log fuel pressure via Zeitronix logging software, which doesn't have RPM or TPS hooked up.

Either way it doesn't really matter as we can just follow boost and fuel pressure.

Here is one instance. Notice the next gear up, right into boost, the car goes really rich at almost one full point, then goes back to 11.8-11.9 after the initial boost hit.

No abnormal spikes in fuel pressure.

http://datazap.me/u/razorlab/fuel-pr...zoom=3865-4130

Here is a quick full throttle burst, rich at peak boost then going back to normal.

http://datazap.me/u/razorlab/fuel-pr...zoom=6777-6919

and another:

http://datazap.me/u/razorlab/fuel-pr...om=10118-10279

Here is a WOT Pull through 3rd,4th and 5th. In Evoscan so no fuel pressure logged. You can still see the rich dips going into every gear.

http://datazap.me/u/razorlab/misc-pu...2&zoom=208-398

Now I'm wondering if it might be the BOV opening....

 

WOT through 3rd,4th and 5th gears eh? How fast were you going again? lol