FJO 100% Methanol Injection System Build-up (Howard Coleman Style)
 

I'm trying to put together a list of everything I will need to purchase for my FJO methanol injection system based on Howard Coleman's custom system. Below is what I have so far but I think I'm still missing the tidbits.

Question for Howard :) . What type of lines are you using from the regulator to the injectors? I noticed in one pic you had a stailess steel line running from the back to the front of the car but in other pictures it seems like your using the rubber hose from the regulator and at the injectors. Could you clarify on that?

And are you using the FJO splitter for the dual injectors or that NOS one? The FJO one doesn't seem optimal since its splitting at a 90* angle.

Also, where/how are you getting the RPM pickup from for the mapping? Is it hooked up to the AI controller or the AFR module?

Also, how exactly does your failsafe based on AFR work? Does it just open the wastegate?

Again, thanks again Howard for your well explained and documented methanol threads/posts. I don't think I'd be confident putting it on my car otherwise. I'll be sure to post my experiences when I put it on my car too :)

thewird

You need two bungs, one for each injector. Also, is your piping SS or aluminum? You have SS selected.

If I remember correctly, you also need a pressure sensor fitting.

I am using a combination of their supplied tubing and SS tubing. I have SS tubing from my tank to the pump, SS tubing from the pump to the filter, nylon (FJO supplied) tubing from the filter to the pressure sensor, nylon tubing from the sensor to the T-fitting, and SS tubing from the T-fitting to both injectors.

I will have more hardware info dec 17th as FJO returns from the PRI show.

the stainless line was from my first (Alkycontrol) setup. the FJO is black nylon from the reg forward and works fine.

as soon as i received the Tee fitting from Alkycontrol i ditched it and went for the NOS Y fitting. i have used it for 2 years and it has not shown any degradation.

more tomorrow hopefully,

howard

as per FJO:

AI-HD will be sold as a "kit" 100 kits avail early jan. exclusive, for the moment. retailer is Alamo motorsports. info on FJO and Alamo sites is for first iteration HA system and will be updated. approx cost for kit $700 w tank and boost controller in module.

hc

Do you know exactly what is included in the kit besides the AI/boost module and tank? How much of the installation hardware will it have? Again, thanks Howard

thewird

+1

i will know monday jan 5

any thing on the kit yet ?

line was busy yestda twice when i called. i should have the info today/tues

Howard, do you think 2x 700cc FJO injectors would be enough to run my 500R-SP @ 30 PSi? It doesn't flow as much as a 40R but for calculations sake you could assume it does. I have 550/1600cc injectors with the Denso pump.

Also, I was wondering at high boost, how do you know your supplying 80% of fuel and 20% of methanol since you cant test and run fuel only? Is it more of an educated guess with fuel curves?

thewird

"do you think 2x 700cc FJO injectors would be enough to run my 500R-SP @ 30 PSi? It doesn't flow as much as a 40R but for calculations sake you could assume it does. I have 550/1600cc injectors with the Denso pump."

////yes, the 2 700s will work excellently. since meth is fuel you can use as much as a replacement as you wish of course, but the 1400 will solve any knock problems to 30 psi if properly timed and tuned. 550/1600s will not be sufficient to run to 30 psi alone but when combined w the 1400 CC of meth will just work. i would be more comfortable w 850 primaries. i also would be far more comfortable if you had a Kenne Bell Boost A Pump (20 Amp model) at 20% gain on your Denso.///

Also, I was wondering at high boost, how do you know your supplying 80% of fuel and 20% of methanol since you cant test and run fuel only? Is it more of an educated guess with fuel curves?///guess is the operative word. i really don't know/care as long as the tuning metrics look good.///

By guess, i just ment to keep the ratio roughly the same at all boost levels, I know you have to monitor EGT's like a hawk. Thanks Howard.

thewird

any update on this?

Waiting on an update im really interested in the FJO system so if I could buy it as a kit already that would be great...

Chris

Me too. I'd like to get this installed while I'm installing my new motor . . .

:-) neil

the FJO kits should be avail Jan 30 from Alamo Motorsports.

Only 5 more days to go, I'm getting excited :)

thewird

cant find this deal on there website...

Delayed unfortunately lol...

thewird

i wait anxiously

i posted an update on my thread in the 3rd gen section... i spoke w FJO monday and they are just a few days from shipping. i advise anyone int'd to make sure you have a reservation for the first batch at Alamo Motorsports. additional details on the other thread.

howard

Any update ?

:-) neil

water injection
 

I installed a aqua mist in my rx7 twin turbo and is working great went from 255 hp stock to 337 hp with this unit.It is very tuneable and friendly user and ajustable look it up.

http://www.aquamist.co.uk/

thanks fcapo

Are you using the "summing module" ?

:-) neil

water injection
 

Yes, I am. It's the best thing I've done. Works much better than the one supplied with the kit. Contact Richard on this subject and he will be able to explain everything to you.
thanks
Fcapo

For those interested...
 

I got this email today...

I'm sending you this because you have expressed interest in the new FJO
Water Injection System. Please forward this information to anyone you
know that might like to know this. If they reply to this message I'll add
them to the list and keep them updated.

I spoke with Gerald at FJO this week and he assures me that their #1
priority is getting their Water-Methanol kit out the door. To that end,
he lists the following tasks that must be completed:

-Update and print the manual
-Enter components into system and create price
-Take photographs
-Identify quantity available to manufacture

As soon as he provides me with the pricing (preferrably with the pictures
too) we can move forward. Simultaneously, FJO can be kitting the finished
product. At this point he projects they have materials to do an initial
run of 20-25 kits. Mass production will start after that.

More as I know it. I promise I won't withold any information from this
mailing list so if you don't hear from me it is because there is nothing
new to report.

Oh, I'd add one thing. I leave next Monday for Army Air Assault School
(I'm in the National Guard.) I will be gone for 2 weeks, but will leave
ample instruction with the staff to ensure that everything is handled
seamlessly in my absence.

Chris Myer
CyberAuto Group of Websites ==================

What is the e-mail so I can add myself to the list as well as anyone else interested?

thewird

chris@cyberauto.com

I assume that's the one he's been emailing me from. It came to my gmail account and it only tells me the name of the company instead of the email address, but that was at the bottom after some other info.

I had also asked him how long it would be til the mass production kits came out and this is what I got in return...

received today from FJO:

"I'm finalizing the administrative end this week as the WI stuff is #2 on my hit list. I told Chris I'll have the pricing and kit info to him by the end of the week. I want to make the announcement next week and have him start taking orders. I'll keep you posted"

in news on this kit??

Hey howard heard anything? Im just waiting... I got all those e-mails as well but have not heard anything since then... Check the website like twice a week but never see any news on it.

Chris

So, nothing new then? Anyone see anything or get any emails?

re availability...

FJO had a pump leak a couple of weeks ago. the pump had been in service more than a year and was 100% meth. the company halted the distribution, which was just about to ship, and sent the pump to Shurflo for diagnosis.

last week Shurflo provided an answer.. they said the pump failed because it was 100% meth. it is my understanding that Shurflo has consistantly stated that their pumps are not 100% meth compatible.

i do know that Alkycontrol uses a Shurflo pump but they mod it. pretty much no failures on 100% meth. i ran their pump and system for a year w no issues.

i currently run a Bosch "909" pump in my system and while Bosch states that their pump is not compatible w meth many people have done it. i drain it in the winter.

i may call Weldon this coming week and see if they could come up w just the pump we want... we could still run the FJO system without the FJO pump.

i will report in next week on FJO shipping status and other pump alternatives.

my condolences to all on this... hang in there just a bit longer.

howard

Yah, let us know on the pump cause I was looking into that this week too after hearing about the leak.

thewird

Well maybe I'll just get the kit in pieces like thewird and get a different pump to use with it.

I've been thinking more about running windshield washer fluid since it won't freeze in the winter and the tank is already there so I won't be taking up any more space. Any thoughts against that?

I've read alot of your threads on this Howard, and I really appreciate the research and work you've put into this and we're all benefitting from it. I don't remember EVERYTHING from the threads but I try to make the best decision for my needs none-the-less.

I'm still pretty sure about getting mostly FJO products though, regardless of all this.

The problem with the FJO pump is if your using 100% methanol. FJO said if your using a 50/50 mix or winshield washer fluid (which is more water then meth) it will work just fine. You only need a different pump if you ever plan on using 100% methanol.

thewird

Yeah that's true HAHA. I kinda missed that little point. My main thoughts on this though, is to get a kit that IS good for 100% meth, that way if I decide later to go that route I don't have to swap out parts, I can just run it with what I'm using. At the most I'd have to add an injector. Thanks for the advice though, and the reminder haha.

Oh, I also agree with Howard's beliefs on this being a pretty good cure for reliability issues, and I've been trying to convince as many friends as possible that this would be a good idea for them too.

Howard, maybe if you can find us a pump which does not require an external regulator (when using 100% methanol) might be a good idea? Would simplify the system and remove a possible failure point.

thewird

So after waiting for this kit to make it to market, and growing more impatient haha, I started looking at the kit thewird was putting together in post 1. What all do you NEED there? At this point I'm going to use just 1 nozzle, so the T fitting obviously isn't needed. But what about the high pressure sensor? Do you HAVE to have that or is it something for added safety of the system? At this point I'm thinking about just buying this kit in pieces.

They haven't released the second generation AI module yet so you can't get it in pieces either. Unless you want the old model.

thewird

Oh, well dammit! HAHA. I guess I'll just wait then. Thanks!

This is kind of ridiculous... This kit was initially reported to be ready at the end of Jan... It looks like Alamo hasnt put out any new info about this thing either. *sigh*

Personally I'm glad they are taking their time because I wouldn't want anything failing once its installed and then have a blown motor or something catastrophic like that. It just means FJO is making sure they provide the best product possible.

I called and reported my pump failure to them along with my pressure sensor and controller failure. I am running 100% methanol as well. I developed one leak within 6 months; I fixed it with Black RTV. I then developed a second leak in a different place and again fixed it with Black RTV.

The parts that fail are the two internal seals. They shrink just enough to leak. I have a replacement pump as well, but I may opt for a Alkycontrol pump in the future.

Got this email today and ordered mine!

Why did I just have to pay all my bills...This sucks...

Chris

^Yeah, come on man, you should know better than to pay bills?! LOL

I just realized I've kinda hijacked thewird's thread, haha. My apologies, I'm sorry.

Hey Howard, I was wondering where you plugged in the RPM and TPS lines to?

thewird

I connected the tps to black and green wire "pin 3G" on to the ECU
And the rpm to the yellow and blue 2B on the ECU. ( Maybe it was green and blue.)

Anyway, the pins are correct.
It worked great on my kit.

Started mapping it on the dyno today, not the numbers i wanted.
I am at 430 at the wheels at 1,2bar so far.

PS, I am running the 500r aspec turbo.......

Anyone having issues with the FJO boost controller solonoid?

thewird