Manufacturing fuel rail.....Slightly o/t
Turbo Mini Forums

Hi all, i come asking for some advice!

Im currently at cov uni working on the formula student class 1-200 car, and were putting in a cbr600, and i need to build the fuel rail.

Since alot of people make their own on here, i thought id ask any advice, hints and tips, or experience on the best way to make one?

Thanks all!

check my build thread below,

also Paul S's thread here

http://www.turbominis.co.uk/forums/index.p...id=129557&fr=25

i THINK THE EASIEST THING (oops) would be making it in steel and silver soldering it.

Also:

http://www.turbominis.co.uk/forums/index.php?p=vt&tid=172394

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

yeh thats pretty much the same way as im making mine. Turn the bits up and silver solder it together.

Ive seen people make them out of billet. Its drilling the long hole thats the hardest part i guess, people soemtimes make them in 2 or 4 bits and put some pipe in between.

I like the soldring way, nice and light.

Edited by slater on 19th Jan, 2009.

Ahh Cov uni - brings back memories! - who's running the Auto Eng Design Course these days? We didn't have forumla student cars to mess with back then......just Thrust 2 and metro turbo motors on the dyno's - I bet they are still there along with the Rover gas turbine motor?

billet alloy fuel rails would be easy enough given the machines you have available!

If Carling made Mini engines
it would probably be like this one!

Or you can buy fuel rail extrusions that just require drilling etc.

9.85 @ 145mph
202mph standing mile
speed didn't kill me, but taxation probably will

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

hey again all.
Once i thought about it i realized how simple it was, it just sounded daunting at first so feel abit stupid.

Anyway just in case your interested....
I managed to get a suitable sized length of tube, measured up the spacing for it to fit to the plenum, found the center points along a center line and marked them out.

Drilled these out on the mill rather than the pillar drill, its much more stable and meant i could drill on one guaranteed center line.

Then onto the injector housings.....
Turned down to length and width, then onto the milling machining to drill the holes for where it slides over the rail, to make sure this was central, i used a dti in the chuck etc, then drilled out the hole for the injector.

Its ready to be welded and didn't take long at all!

For welding im making 4 plugs to center housings perfectly.

Some pictures...

not seen one done like that before, thats a great solution. :)

its a very simple way of doing it, i would never have been able to think of something like that, do you have a build thread mate, ?

Yes i moved to the darkside

Instagram @jdm_brett

thats the same way MSD is offering parts for, but making your own parts will be cheaper, i guess

how are you holding it all together? you normaly have 4 clips that go over a small 'lip' to hold the injectors into the rail. I guess you could just rely on it being bolted down tho.

Right, bit of an update.

Long story short.... got it welded ( and learnt to tig after so that came in useful! ), had to make some injector hats for the plenum and got it put together.






Moved my mounts once, fuel rail sits solid but on a pressure test it pissed out of 3 at the top edge, so im going to put longer brackets on to adjust the angle of the threaded bar you can see in the pictures (this pulls it down)

first mounts


Next mounts were on the other side to pull it down more square


Im going to have a play and try and force some beastier o-rings inside tomorrow too, wish me look!

Wow wow wow... you never said it looks like that... more pics...more pics...more pics... lmao
come on guys get chanting

Yes i moved to the darkside

Instagram @jdm_brett

slater - the injectors dont have anything to 'hook' it onto so have to rely on bolting it down, the first o rings aren't sealing, so i tried some different dust covers as the current ones dont fit too tight, this might have worked but they had slight cutouts in them so fuel came out of there.

Tomorrow i'll be trying to force in some bigger o rings to get a better seal and make some new tabs to pull it square,

wish me luck!

good news, after some fettling and slightly bigger o rings, she sealed to 4.5 bar!

I always wanted to do fsae at college but where i went was always too tight to do it!

strange they didnt seal, what size did you do the holes?

i did mine 14mm, and then put a bit of a taper at the entrance with a cone cutter just to help the seal start. with a little bit of grease is sealed fine.

measuring from an original rail, 12.7mm, but this had to be bored out on the lathe, i was busy at the time so my mate bored them out after i drilled them and they werent too accurate, different arrangement of o rings sorted it rather than the original ones