after getting the kids to be i decided that rather than spending another evening in the anaesthetic arms of the one eyed lodger i’d go through all the stuff in bags and boxes in the junk room downstairs…

i got on with a few jobs i knew needed doing, sorting out which of the garret turbos to use…

although i think one is stighly better than the other, after getting half way through changing over the exhaust manifold from one to the other and then realising that i also had to change the studs over too (the better turbo has studs that are too short for the manifold from the other one…) i also realised that the alignment of the exhaust input flange and the oil in and return were 180 degrees out for what i wanted so rather than go through the whole palaver i decided to stick with what was ok in the first place….
(i hear you miles, i hear you! it aint broke yet so i’m not going to bother fixing it…)

so after that i got on with the Kjet injection system. I have one and a half or nearly two complete systems, one saab 900 and one golf. i want parts from both…

i’m taking the guts of the injection from the saab, it was a turbo model so maybe this is good. it is a good omen on my planet anyhow… the huge mechanical airflow meter is like a big paddle on a pivot in the base of the airbox, this changes the fuel pressure in the fuel distributor head on top of the airflow meter (i’m probably using all the wrong names and descriptions but i haven’t finished reading all the kjet manuals i found on the web…
i never read manual for software or computers until something won’t do what i tell it so i reckon why start now (actually there’s loads of reasons… 1. if software crashes you just reboot. i found out last year that you can’t reboot a spun bearing 2. software very rarely causes fuel fires )
so anyhow what i want is the saab airflow meter on the rectangular golf style airbox…
so here we go…

remove (or drill out the rusted ones) all the bolts and separate the unwanted airflow head from the top of the box…

get the new airflow head, twiddle with some replacement bolts etc and hey presto, another job done…

i still have to fabricate up the stuff on t he ends of the intake manifolds for the kjet injectors (completely mechanical, unlike the last injection setup on the bus… no fancy solenoids here, basically the injectors just dribble all the time and the airflow head changes the fuel pressure to increase or decrease the dribble, hrmph.. technically speaking)

i also found a larger throttle body that i’d forgotten about, from a rover i think, its about 6 or 7 mm larger diameter than the 2,1 wasserboxer one i was going to use, cleaned up ok, we’ll see what fits… i could always modify the wasser boxer one and put in a bigger butterfly (yeah right…)
there are a few more bits i need but it’s pretty much there…

so i layed it end to end for the first time and i felt much better, a kind of ‘this might actually work’ feeling.

here’s all the gear….
starting at one end of the system..going anticlockwise from the right of the picture

• the garret turbo,(hot side and cold side)
• recirculating dump valve (ebay special)
• the saab 900 kjet injection head on the golf airbox
• ford rs turbo intercooler (ebay special)
• rover throttle body
• injection manifolds and plenum chanber from 2.1l injection wasserboxer

i still need hoses and some other stuff like… erm, i forget…
ah yes, boost gauge and boost sensor, bits of exhaust manifold pipework from the baja header to the inlet flange on the turbo and some other stuff,

the only thing not shown is the fuel pump and pressure acculumator assembly that i have, thats form a golf but i’ll swap bits (like the high flow filter from the saab (in the picture)) before bolting all together…

more later!

d