I wanted to let everyone know the "REAL" costs of my ITB set up. All I can say that it had better make a gazillion HP and make some cool noises and give me instant throttle response and wow everyone in the world.

It has been a longer than expected road but we will fire the car up tonight for the first time with the ITB Hayabusa setup. Everything fit according to the design. The big parts cost about what I was expecting, but it has been the nickel and dime stuff that has taken the toll in time and money.

Costs:

Hayabusa Throttle Bodies - $321.00 Cdn.
Megasquirt - $482.00
Aluminum Tubing - $40.00
Manifold Mounting Plate - $80.00
Welding - $120.00
Inlet Bells - $80.00
Fuel Rail - $44.00
Vacuum Line Bungs - $6.00
12x1.5 Tap - $42.00
14x1.25 Tap - $47.00
37/64 Drill - $39.00
Viton O-Ring Kit - $7.00
Assorted Nuts and Bolts - $20.00
Wiring and Connectors - $45.00

Total Cost - $1,373.00 Cdn.

Pluses, it looks great, it should make great power, it is very different for North America to have on the car. It has taken a ton of work by 2 talented people with a lot of help from outside sources. Would I do this again?

ABSO-FREAKIN-LUTELY!!!!!!!!!!!

Just for the wow factor alone it has been worth it and Dave and I have learned a ton in doing this about rotaries, about tuning and I have worked with some very good people in making this happen. Honestly it has been an immeasurable help to have Dave Salt help put this together as his electrical engineering knowledge and application experience has prevented a number of problems and sped up the build a lot.

I will let you guys know how it all goes when we get it running.

Eric

 

Can't wait to hear the car again.

 

Yeah those taps really make the price skyrocket. I apparently needed 3/8NPT for the Haltech, and M14x1.5 and I never had to use the damn M14, so I bought 100 bucks in taps only to use 50bucks. Same goes with the electrical supplies, all the additional crap kill the budget in a hurry.

It should be a pretty wild ride, and sound awesome.

What about tuning the MS? Shouldn't that be in there aswell? :p

 

Eric, what did you use for a fuel rail? I'm looking at a few aftermarket jobbies that accept standard injectors and are pre-plumbed for -6AN fittings but they are fairly expensive, $150-$200. Just ordered 50 feet of -6 line for $180 US shipped, God bless America. Where again did you get your inlet bells?

 

DIBS on the second one!!!!

Since you said you'd do it all over again.

 

hmm, that's not too bad actually. i mean it is a pretty sweet setup
i'm guessing you purchased the MS pre-built? some cost can be cut by assembling it in DIY form.

anyway, can't wait to see how it works out. post results/pics/video, etc. thanks for posting prices.

 

Dave installed the Megasquirt last night and ran through all the tests. The injectors fired (you could hear them clicking), the plugs fired (leading and trailing!!!) Dave set the CAS and methodically went through all of the startup procedures on the laptop.

I plumbed up the new oil pressure gauge, routed the injector lines, cobbled up the throttle linkage and had to change all of the fuel lines as the last setup was the Holley and everything was different. I ended up using the last bit of my extra fuel hose to re assemble the fuel rails and the length left over wasn't long enough for the return hose. It was too late to find more, so the actual startup is delayed until tonight.

We ended up cranking the car over, with the fuel pump off, to build oil pressure and to make sure the starter interlock worked and all of the rest of the stuff worked. We got 30 lbs of oil pressure cranking, but it took a while to build pressure as we had to refill all of the oil lines and the new filter (a Motorcraft Ford Motorsport one with anti drainback and very fine filtering element, for all of you keeping score at home).

Everything was dry and looked good so it is off to NAPA for about 3 feet of 5/16 fuel line, about 6 feet of teeny tiny vacuum line and we should be good to go tonight.

In regards to the questions asked, the bells came from Orient Express and they are the same ones as used on their Hayabusa Pro Stock bike. The fuel rail came from a place called Ross Machine. It comes as an extruded rail that you have to cut off and drill and tap yourself. It is only $11.00 US a foot, but with duties, etc... it runs about $20 Cdn a foot. The 'squirt was purchased as a kit and assembled by Dave. The cost includes the daughterboard that will allow us to run the stock CAS and run trailing, the shift light and traction control, the case, the extra resistors to allow the use of pre-89 injectors, extra heat sinks to make the unit bullit proof, the Mega-stim and upgraded connectors to improve the durability of the interfaces. I also included the duties and taxes on all pieces imported from the U.S..

Shane, sorry buddy, I will only do this again for myself. If Dave and I had to add in all of time costs to do this and charged $20 bucks an hour we would have to add an extra $2000 to the cost for another setup. HE!! the head scratching, cutting and shaping trauma alone is worth.......... ONE MILLION DOLLARS..... alone, LOL.

Eric

 

ah, ok that cost makes sense then for the MS. interesting you mention using traction control! people have also done launch control (two-stage type i believe), might want to look into that also if you have any races with standing starts.
also i'm assuming you are using the Megasquirt 1. the Megasquirt 2 CPU is now working for rotary and gives more features and tuning ability. it's simply a daughterboard, no need to rebuild the whole thing.

 

Looks like I'll need to download some software...

 

is that in dollars or canadian?? if not dollars how much will it be??

 

So, last night I hooked up the vacuum line to the brake booster, the fuel return line and tried to cobble up a throttle cable. I also restabbed the CAS 3 teeth off and hooked up the jumper battery to the new small race battery. Dave hooked up the Megasquirt and went through his check list and gave me the thumbs up to crank it over.

I cranked it over until I had oil pressure (it seemed to take ages) and turned on the fuel pump. Dave started saying that we had a couple of leaks in the fuel fittings. I had to tighten up the pressure regulator fitting on the end of the rail and we tried again. NOTHING.........WTF?????

I went over the fuel system again and Dave checked the 'squirt over. Hmmmm...... what the heck, I put 2 pulsation dampers in the system, I had no fuel pressure. I took out the damper on the end of the secondary fuel rail, added a pressure regulator from an S5 I have. We tried it again.

POP, Burp , POW, POW, Burp. It made noise at least. Time to break out the timing light. Yep still one tooth out, so rather than replunge it we just cranked the CAS to the max and tried again. Turn on the electrics, turn on the fuel pump, push in the clutch and push the starter and ...... and ..... and......

BRAAAAAP, BRAAAP, WAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAhhhh..... It started just like it had been running 2 seconds before. No pops, snorts or burps.

GAWD was it loud. Far louder, crisper and way more annoying and angrier sounding than last year. I freaked out. I jammed the Kill Switch and it all shut down. Well it was after 9 in a really really residential area.

Everything looked dry, the oil pressure had shot to about 130 lbs. Dave and I looked at each other and smiled. A great sense of relief and all of our work was correct. Just a few more issues to clean up like tidying up the injector wires, building a proper throttle cable and just some general cleaning up. We also have to add the Super Trapp to the Borla just to get the sound levels down to a reasonable level so that we can put a basic tune in the car before we head to the dyno.

I am really buzzed now.

Eric

 

Right now it really doesn't matter. And FWIW, we have dollars too, they're called loonies But I'd imagine its Canadian.

Congrats Eric!!

 

Woohoo!
The car is alive and kicking!

Can't wait to see it again.

 

Congrats! Looking forward to Toronto!

 

So am I, sorta. As I didn't do either of the first 2 race weekends, I didn't qualify for the event. There are over 95 cars registered and ASN-FIA only allows 42 cars on track. I think that about 5 cars are spares as well.

What I have is an opportunity to have my car sit in the Toyo booth for the weekend. Great for my sponsors, not so much fun for me. Oh well, need to wait for Calabogie the end of July.

Eric

 

great to hear you got it started up.

what Calabogie event are you going to?

 

If I can get the car quiet enough, I will be at the MCO Race Weekend the end of July. It looks to be a slower weekend for the CCTCC, only about 50 cars,LOL.

Eric

 

Eric,

Congrats on the successful startup! After seeing that meticulous MS build, I didn't expect you'd have much trouble.

Roger.

 

congrads ...

but seriously ... i couldn't be ineterested in one too ... I'm need something to go with my 2 speed rotrex supercharger