New Classic Mini Project - Fuel Injection!

Discussion in 'Classic Mini' started by Minidave, Aug 21, 2020.

  1. MCS02

    MCS02 Moderator
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    I hope they don't delay it agin!
     
  2. Minidave

    Minidave Well-Known Member
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    Me too, but I went ahead and ordered the small 2bbl version, it's in stock so I should have it next week sometime, so maybe I can make some real progress. I'm excited to fire one up and see how it works.
     
  3. Minidave

    Minidave Well-Known Member
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    #23 Minidave, Oct 8, 2020
    Last edited: Oct 8, 2020
    The Nikki manifold is by far the best all around fit and function, so that's what I will use for the 2bbl setup, I may try and use the original side draft manifold setup for the single bbl on the small motors. I still haven't gotten the 1bbl EFI unit, but I did receive the 2bbl unit and I've been working on figuring out how to fit it to the Mini engines. I will do initial setup on the 1098 in the engine stand, but I plan to use my 1275 in my Green Mini as my test mule once I get it all figured out.

    IMG_20201007_164912R.jpg

    I drilled and tapped a plate to put the temp sensor in the back of the head where the heater tap would normally be - just for test purposes on the test bed engine. I think if I install this on the green Mini I'll bore and tap a hole right into the end of the cylinder head - if I wind up not using it on that car permanently I can always just plug it as it's a simple 3/8 pipe thread.

    IMG_20201007_143414R.jpg

    The 2bbl unit is almost a direct bolt onto the Nikki manifold, I will have to open up the throat of the manifold to match the throttle bores - I'm undecided whether to use a phenolic spacer under the EFI unit or the aluminum I already have - but I have some phenolic material coming in case and I have a friend with a mill to shape it correctly. I will need to slightly modify the stud holes to match the Nikki stud pattern, but it won't take much.

    I also ordered a 6" pancake air filter to fit the 2bbl EFI unit, no idea yet what the smaller 1bbl will need. Delivery on that has been pushed back to the middle of the month - I'll believe it when I see it - or when they charge my credit card I guess!

    I had hoped to set up the 2bbl unit with the accelerator linkage on the left, but it does not fit there, so I'll need a longer acc cable when I mount it on the green Mini. I'll also have to pull the fuel tank to install the return line bulkhead bung. You can see in the pic the fuel pressure regulator sticks out too far and will hit the valve cover.

    IMG_20201006_132758R.jpg
    IMG_20201006_133018R.jpg

    I ordered a bunch of O2 sensor bungs to weld into the exhaust pipes - I'll need one for the header in the test stand and for the green car - then If I build one of these for a customer I'll need it for them too - so it'll be good to have some spares on hand - I found them 5 for $20 including the plug....shipped.

    The weber 2bbl intake manifold I ordered simply does not work, the center pipe on the headers foul the manifold, and I tried two different sets of headers - neither works. It's going back.

    More as it happens.
     
  4. 00Mini

    00Mini Well-Known Member

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    This is going to be a very interesting project.
     
  5. Minidave

    Minidave Well-Known Member
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    #25 Minidave, Oct 10, 2020
    Last edited: Oct 10, 2020
    Well, looks like the rest of my project is finally getting into gear, as I've had an email that the single bbl unit has shipped at last. Tune in next week for some pictures!

    Also got the weldable bungs for the O2 sensors, and an air filter assembly is also due today - I don't know if it will fit the single bbl unit yet, but I think it does.
     
  6. Minidave

    Minidave Well-Known Member
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    I sent the Nikki manifold off to the machinists today, we decided it would be better to relocate the studs in the manifold rather than modify the EFI unit, so that what we're doing. He's also going to match the bore to the throttle plates, and make a couple of phenolic spacers for me.

    I decided to weld the O2 sensor bung into the front pipe on the muffler, that way I can use it with any of the headers and I only have to do the one....the sensor just unplugs so it will be easy to move from one setup to the other.

    More as it happens - getting closer to seeing if it will run now.
     
  7. Minidave

    Minidave Well-Known Member
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    Over the last few days I cut the adaptor plate out for the single bbl EFI unit to fit the Nikki manifold. I sent the manifold off to a machinist friend who reset the mounting studs to fit the 2bbl EFI unit so I had to modify the mounting holes I'd already drilled to fit the original Nikki spacing to fit the single bbl unit to the manifold. My plan is to run the single on the test stand first to figure out how to make it all work, then put the 2 bbl unit on my 1275 motor in my Racing Green car to see how it all works in an actual car, since I can't put any load on the motor in the engine stand so the unit can "learn" a run map.

    IMG_20201017_151207R.jpg

    So I now have both the single and 2 bbl units fit to the manifold so I can switch them out easily. My machinist buddy also has the maps saved in his mill so he can cut spacer plates out of aluminum or phenolic material for me, as well as convert the manifold stud spacing easily. He also matched the opening in the Nikki to the bores of the 2bbl.

    IMG_20201016_151235R.jpg

    All of this is just preliminary to actually fitting it to an engine and a car. An SPi manifold can be made to work with a little bit of surgery here and there, but the Nikki is even easier and it fits better. I was able to lop off a water jacket boss on the bottom of the SPi manifold and now it will work with either exhaust header too.

    So, single bbl units for the small engines - 998 and 1098, 2 bbl unit for the "big" motors is the plan - Holley says the single can support up to 200 hp but I dunno, it doesn't seem like it could flow enough to really build some HP in a 1275 or 1380 motor with a nicely flowed cylinder head.

    My buddy forgot to cut the phenolic spacer for the 2bbl unit - it's only needed to provide clearance for some of the linkage and other bits - who knows maybe it's a good idea to have it for heat insulation too? If so, i can make one for the single bbl version too, there's plenty of room between the top to add an air cleaner too so, another 1/4 or 3/8" of height won't matter.

    At this point both projects are on hold for a while. I have a car coming in the shop the 26th for a suspension overhaul and an engine being delivered around Nov 1 that will need to be torn down and parts sent off to the machine shop, and I'm back working on the Inno to get it up and running. I'm down to a short amount of time before I'm laid up in January with my knee replacement. I'm still only able to work a little here and there, but I'm determined to get these projects finished.

    The EFI project will have to wait.

    Linkage on the single bbl is going to be interesting, and I may have to build some brackets and such to get it to work - no real idea how to do that yet, I tried the single bbl on both ways as it will fit either direction and it looks like having the linkage off the back of the manifold will work the best but I won't know for sure till I try it in a car - and right vs left drive may make a difference too. The 2bbl unit will only fit one way, so I'll just have to engineer for that mounting position. I'm excited to see it run and work, but I have to finish the other commitments I made first.

    IMG_20201017_151419R.jpg
    IMG_20201017_152851R.jpg
     
  8. old81

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    Wow, anyone else looking forward to late Spring when Dave gets back on to this project, I like elegant work. :). Don
     
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  9. 00Mini

    00Mini Well-Known Member

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    Looking forward to seeing these on running engines.
     
  10. Minidave

    Minidave Well-Known Member
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    Me too! Perfect winter time project.....too bad it has to go on pause for a while.
     
  11. MCS02

    MCS02 Moderator
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    I hope you keep getting stronger and your knee replacement goes well.
     
  12. Sully

    Sully Administrator
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    Absolutely - love these projects and the craftsmanship. Awesome work as always!
     
  13. Minidave

    Minidave Well-Known Member
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    Thanks guys, more projects in the works.....newest one set to arrive Monday - on the coldest, rainiest day we've had all fall, and the second one on Tuesday - the second even colder and rainier day! Then Wed it's supposed to be nice again - typical fall KC weather.

    We had 85* Thursday and a high of 41* today!

    Lots to do before the Knee date, but I doubt it will all get done in time - none of these projects is time critical fortunately.....if done by Springtime it will be soon enough.

    Did you all know the hottest it ever was in Reykjavik was on a July day where it hit 76*! And yet the usual lows in winter are high 30's and low 40's due to the gulfstream waters that go north along the coast and out to the northern sea.
     

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