1776 Mexi EFI Turbo build

[vwgillybilly]

Hi.

After shelving my 1600 carb turbo set up last year after I sold my old bus I'm now ready to delve into the world of EFI!

With the old Renault 5 set up I got sick of faffing all the time so I'm jumping in to EFI!

Here are the parts I have so far...

Mexi EFI TB & intake, cold air valve, fuel rails, rear tin with fuel lines & loom connectors

Ford RS Turbo 250cc 'blue' injectors - to get me started at low boost!

Taylor Machine Services billet VR sensor bracket

Berg Equaliser pulley machined for 36-1 by Taylor Machine Services

Home machined stainless dissy plug

Bosch 044 pump with Audi 80 filter

Yamaha R6 cops & loom

Still to come/buy...

Turbosmart/Sytec rising rate regulator

MS2 v3

Techedge wideband


Engine specs will be...

1776

Balanced stock 8 dowelled crank, stock rods, stock cam Berg 30mm oil pump, steel pushrods & KEP Stage 1. I'm debating fitting a TCS 10 cam & Berg straight cuts that I have but I don't know if it's really worth it? What do people think?

Full flow with cooler

CB 044 heads with 35 & 40 (inlet) valves & Autocraft 1:25 rockers

Schwitzer S2 turbo ( I want lazy boost!)

CB header & wastegate

I want the engine to look clean like my 1600 did, I don't want to run mega boost (10psi tops really) & want a nice cruisable engine that's clean running with a bit of power to spare!

This is going in a fairly heavy bus (1960 Westy) so it's never gonna be a rocket ship!!! I have upgraded the transmission to a Rancho pro-street over the winter & had a taller fourth dropped in (.82 & 3.8 r&p) so it should be ok to cruise.

What do people think of my specs? Obviously there's scope to upgrade a few things but that can come later if needed. I'd like to think I've played it safe but I'm open to suggestions as always!

I'm aware of the Mexi tb & runner limitiations & do have a German plenum lying about but I really want to use the Mexi stuff for a nice o.g (ish) look!

I forsee the idle being a pain but plan to run a cold air valve as Chip birks did with his set up. Does anywone know if the o.g Mexi 2-wire valve will work? I cross referenced part numbers & it seems to be used on a fair few VAG cars.

Thanks.

Gill.

[Clonebug]

Watch with the big oil pump.....I had over 100 psi cold and an expanded filter with my 26 mm pump.
I had different bypass springs installed to see if the pressure would be lowered.
I had to use 5-20wt oil to get the pressure down to a reasonable amount.

[yvre]

Stock cam. I'm debating fitting a TCS 10 cam & Berg straight cuts that I have but I don't know if it's really worth it? What do people think?

Why do you want to run a stock cam in this???

I forsee the idle being a pain but plan to run a cold air valve as Chip birks did with his set up. Does anywone know if the o.g Mexi 2-wire valve will work? I cross referenced part numbers & it seems to be used on a fair few VAG cars.

I'd also like to know.


Sounds like a great project!

[vwgillybilly]

Thanks Clonebug, I used this pump in my last 1600 Turbo motor & it was fine. I have a Berg relief pump cover so I'll see how it goes.

Yvre I used a stock cam in the last motor & liked how it drove, I'm not really looking for a revvy engine. 5.5-6k will do. The big Schwitzer S2 I'm using won't wake up until 3k so ideally the engine will behave quite well & cruise well off boost then have that kick when needed!

I'm open to suggestions with the cam & am also considering the hydraulic Mofoco set up.

In my head I think I have sussed the idle situation with the Mexi tb, MS has the 2/3 wire idle control so it should work the Mexi valve. If not I may have to mechanically open the butterfly with the stop screw to allow more air in at idle. Either way it should work.

I could use the German plenum I have but I think it looks ugly & I have to buy the manifold ends etc.

Thanks.

Gill.

[Chip Birks]

I think the main difference between the valve I used, and the mexi one is the physical makeup. Mine was metal, the mexi one is plastic IIRC. Both are 2 wire valves controlled by PWM. It worked great. I could start my car at -0 degrees F. without touching the throttle. You just need to add the transistor to the MS. Like it says in the Extra manual.
http://msextra.com/doc/ms2extra/MS2-Ext ... .htm#Fidle

[John_S]

somebody else in england doing EFI and turbo , good lad
if u need help or advise give us a bell (i can also supply u megasquirt or help u setting it up )

[vwgillybilly]

Thanks John.

Do you build the Megasquirt ecus then?

Could you send me your number please?

Thanks.

Gill.

[Humpty]

Sounds like a build very similar to my own.... 'cept mines only 1641, and my bus is 68 Micro.... The gearing your running is where I'm at right now.... Trying to figure at the final drive for better cruising and a 205/60-15 tyre.... Was considering either going with a SSP trans or rebuild a 5 rib I have sitting here.... Boost wise looking at the same sort of plain.... Stock cam and heads, with a T25 Garret to blow through the mexi TB/MS1 I got from Mario a while back.

Looking forward to seeing your progress.

[vwgillybilly]

Sounds like a build very similar to my own.... 'cept mines only 1641, and my bus is 68 Micro.... The gearing your running is where I'm at right now.... Trying to figure at the final drive for better cruising and a 205/60-15 tyre.... Was considering either going with a SSP trans or rebuild a 5 rib I have sitting here.... Boost wise looking at the same sort of plain.... Stock cam and heads, with a T25 Garret to blow through the mexi TB/MS1 I got from Mario a while back.

Looking forward to seeing your progress.

Nice one - I am your progress too!

68 Micro - nice bus - I have one too, except mines a rusty UK RHD!

I'll put some pics of the hardware I've aquired thus far! Almost there, Yamaha R6 coil sticks arrived this week!

Gill.

[Boardpaul]

Would be great to get a look at this and discuss the pitfalls you have had with the carb route.
Will be in Chesterfield regularly shortly.
Cheers

[vwgillybilly]

No probs Paul. You're welcome anytime. Still have the remnants of the carb turbo set up but sold the carb & inlet some time ago. There aren't any pitfalls mate, just limitations of jetting etc. I could have got mine better, but in my heart I knew EFI was the way!

I did 4k on my set up in a bus & never missed a beat apart from the odd glitch through my tinkering & over expectations. Realistically a mild 1600 should make 125bhp I never had mine dynoed but the closest indication I got was my mate not being able to pass me in his 140bhp T4!

Pm me & I'll reply with my number!

Gill.

[vwgillybilly]

Ok so I got my MS 2 v.3 ecu & most of my hardware sorted now. I had to use a bit of creative thinking to get my Mexi plenum to mount along with my Taylor Machine Services vr bracket but in the end I just split the difference of the vr bracket thickness between the manifold & bracket & milled them accordingly.

I removed the missing tooth of my machined pulley equal to 90 degrees after tdc as the vr bracket is at 15 degrees after tdc, so 90+15 degrees.

I had the Mexi stuff soda blasted which turned out nice!

Gonna mount the FueLab reg on the left hand side of the fanhousing & run the fuel line behind the intet runners for a nice clean look & easy access for adjustment. I got the FueLab 525 model regulator as it has horizontally opposed ports for a neater look.

Just found out the Yamaha cops I have are CDI so a no go... need to source some form a 2006 onwards bike which are the inductive type.

My alternator packed up last week so whilst fitted that I installed the pulley & Mexi alternator stand. So now I can install my efi & learn the basics without turbo so I don't kill it! Then over the winter (when my 68 bay project is hopefully finished) I can crack on with fitting the turbo.

Here's how things stand for now! Still need Bosch a 044 fuel pump & wideband controller.















Gill.

[bazibbo]

Looking good Gill.

Love the way the machined pulley does away with the nasty 'bolt on look' when you stick a toothed wheel on the outside of yer pulley.

but then I am a tart for form over function.

[vwgillybilly]

Looking good Gill.

Love the way the machined pulley does away with the nasty 'bolt on look' when you stick a toothed wheel on the outside of yer pulley.

but then I am a tart for form over function.

Thanks Baz!

But if form follows function then it's alright! Hopefully it should be alright, that's the beauty of steel pulleys!

Hows things with yours mate? Did you get it mapped?

I'm close to starting the build but I want all the hardware sat waiting as I don't really want my bus not running for long as I have to move it in & out of the garage to do other work. Gonna install as much as I can in situ with the carbs & distributor so I can still run it. Bowling & Grippo even recommend setting up/learning fuelling & ignition one at a time but with the Mexi hardware & how my vr sensor bracket fits this would be difficult.

Things took a turn up for the books over the weekend as it turns out a guy who contributes on here & on VZI (username Emtee) actually lives on the next street to my girlfriend in Sheffield so I called round to his on Sunday to check out his home-brewed 2.1 MS2 v.3 set up! He even drinks in her local! He took me for a spin in his 67 bug with only about 80 % throttle available & all I can say is amazing! It nearly snapped my neck! Hopefully he's gonna help me with mapping etc & I'll provide the beer!

Gill.

[bazibbo]

Wow that's pretty lucky.... I'm billy no mates, fumbling around with things I don't understand. I'm using 'facetime' on my iphone to run through everything with my technically minded brother in Cornwall... just a case of staying in range of my broadband....

Crack on Gill, Leeds VW festival is just around the corner, and not a million miles away from you.

I'm just about to start mapping.... I'll update my thread.