Re: Potential Fuel Pressure Regulator Solution
 

With the way winter is shaping up here in Northern Virginia looks like it will be some time before I can get around to seriously road testing this fuel pressure regulator. Therefore, if anyone is interested in testing it out on their ZR-1 I will gladly provide it as no cost loaner for a reasonable period of time. Afterwards I would like it back to perform a full tear down inspection.

Re: Potential Fuel Pressure Regulator Solution
 

I've said this before Phil but thanks for leaning forward to promote this hobby. GC

Re: Potential Fuel Pressure Regulator Solution
 

It amazes me just how clever and smart some people are. Wow.

Re: Potential Fuel Pressure Regulator Solution
 

What is the latest? Are you still looking for someone to install your prototype?

I can pull a plenum in a few minutes and install one as you like just to see how it functions. I also have one or maybe more FPRs (at least one that has failed) I removed from a ZR-1 that was flooded with gasoline.
I will go and check that now.

I like the mechanical looks :thumbsup: :thumbsup: Very Nice Phil.
https://cimg4.ibsrv.net/gimg/www.cor...9ba11f529e.jpg

Re: Potential Fuel Pressure Regulator Solution
 

Thanks Cliff, I’ll send it your way this weekend. Send me your failed one after this one proves out and I will incorporate any lessons learned


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Re: Potential Fuel Pressure Regulator Solution
 

Cliff,
Let start with the one I have completed so we can gain some quick experience then go from there. Work is tying me up at the moment and don’t have much free time for the next few weeks.


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Re: Potential Fuel Pressure Regulator Solution
 

Cliff/Phil,

Let me suggest that u should add datalogging before and after installation. This way we can judge if the FPR has had any unforseen affect on fueling.

Re: Potential Fuel Pressure Regulator Solution
 

Cliff,

I made a suggestion. Not forcing anyone. Frankly, datalogging would represent a simpler not more complicated means of confirming results IMO. I’ve had experience with any number of “changes” that should not have affected engine operation and yet they require modifying the calibration to some extent ie changing injector brands even if they supposedly flow the same.
This is exactly what I would do were I to install one of these.

Re: Potential Fuel Pressure Regulator Solution
 

Well if there is a need for analysis, let me know. I can provide the tools.

Re: Potential Fuel Pressure Regulator Solution
 

Phil,

U mention that the pressure range of the 016 FPR is almost identical to the stock regulator. Can u quantify the variance or was it totally negligible?

Re: Potential Fuel Pressure Regulator Solution
 

Cliff,

Excellent. Thanks.

Re: Potential Fuel Pressure Regulator Solution
 

WTG Cliff and Phil. GC

Re: Potential Fuel Pressure Regulator Solution
 

Wow! Heroes!


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Re: Potential Fuel Pressure Regulator Solution
 

You guys are amazing


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Re: Potential Fuel Pressure Regulator Solution
 

Awesome ! Excited for this !

Re: Potential Fuel Pressure Regulator Solution
 

:cheers:

Re: Potential Fuel Pressure Regulator Solution
 

Reports coming in from Dynomite are quite encouraging
Catch up here: https://www.corvetteforum.com/forums...post1596384563

Re: Potential Fuel Pressure Regulator Solution
 

Great work guys! Can’t wait to see the final product. I see the utility of using the original housing with the new Delphi regulator. Any possibility of getting an adjustable version?
H
:cheers:

Re: Potential Fuel Pressure Regulator Solution
 

Would consider it, know of a good one? No noisy Chinese knock-offs.


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Improved Fuel Pressure Regulator
 

The Improved LT5 Fuel Pressure Regulator

As far as adjustable version......there are at least 3 Delphi Fuel Pressure Regulators of various pressure ratings that one can change out in a matter of minutes without removing the plenum.

Phil only modified the Fuel Pressure Regulator Stock Housing making it easy to insert anyone of several inexpensive Delphi Stock Fuel Pressure Regulators :thumbsup:

Initial Fuel Pressure Tests of Improved Fuel Pressure Regulator (IFPR).

A. With Engine On at Idle (850 rpm) vacuum line connected to IFPR.
Engine idled at 850 rpm with Fuel Pressure Reading 40 psi (Left photo).
B. Engine Idled at 850 rpm with Vacuum line to IFPR disconnected
Fuel Pressure Reading is 52 psi (Right photo).

No Leaks......

https://cimg6.ibsrv.net/gimg/www.cor...07aae4ba34.jpghttps://cimg8.ibsrv.net/gimg/www.cor...9a602d432e.jpg
https://cimg4.ibsrv.net/gimg/www.cor...189605ba83.jpg
https://cimg1.ibsrv.net/gimg/www.cor...530c272c90.jpg
https://cimg9.ibsrv.net/gimg/www.cor...6b64a3dece.jpg

Re: Potential Fuel Pressure Regulator Solution
 

Cliff is it me or does that piece look more "Stock" than stock? It just follows the form factor better like stainless oil cooler lines. It looks like that was like it was suppose to... or meant to... look like as "serviceable" vs. non serviceable. GC

Improved Fuel Pressure Regulator
 

LOL........I am not sure what you are thinking but this IFPR that Phil designed with the Allen Head screws is a very nice piece of work and is a perfect fit with the other Allen Head Stainless Steel bolts on the Plenum and coolant pipes.

And it is completely serviceable without removing anything else. The only item you would want to service would be the Delphi Fuel Pressure Regulator that Phil installed in the modified Stock Fuel Pressure Regulator Housing. I expect that to change out the Delphi would take a couple of minutes with only a small Allen Wrench.


https://cimg2.ibsrv.net/gimg/www.cor...ed552e4baa.jpg

Re: Potential Fuel Pressure Regulator Solution
 

A couple of minutes IS a total win ! :saluting:

Improved Fuel Pressure Regulator
 

The Delphi was rotated just a tad counterclockwise in the photo which only took a minute to loosen the Allen Head screws
It definitely is a thing of beauty :thumbsup::thumbsup:

https://cimg2.ibsrv.net/gimg/www.cor...79076b05f2.jpghttps://cimg2.ibsrv.net/gimg/www.cor...ed552e4baa.jpg

I was trying to hot wire the Fuel Pumps using the Fuel Pump Test Connection which for the early 1990 (first 500) Marc says resides to the right of the battery. Marc also said it is sometimes hidden. I removed the battery and yes......it is definitely hidden as it was nowhere to be found :D

So....to test higher fuel pressure I just removed the vacuum line at idle and got the 52 psi fuel pressure. Again......I have run into a couple Failed Fuel Pressure Regulators and they DO require removal of the Plenum to fix. NOT ANY MORE :dancing

DO NOT TOSS A FAILED FUEL PRESSURE REGULATOR

Improved Fuel Pressure Regulator
 

Phil.......can I just keep this one :D

https://cimg2.ibsrv.net/gimg/www.cor...ed552e4baa.jpg

I have been driving every day and even a 100 mile trip.....
Perfect all the way.....NO ISSUES.....

Just let me keep this Improved Fuel Pressure Regulator on the ZR-1 for a while longer at least until mid April if possible as I will park this 1990 #72 for a while at that time.

https://cimg6.ibsrv.net/gimg/www.cor...3a1e1fd87b.jpg

Re: Potential Fuel Pressure Regulator Solution
 

Sure Cliff, keep it as long as you want.


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Re: Potential Fuel Pressure Regulator Solution
 

Dremel the bracket for nipple clearance I'd think. Orientation of the FPR looks to be fine.

Re: Potential Fuel Pressure Regulator Solution
 

I'm thinking a couple minutes counter-clockwise and you'll have issues with the retention ring hardware. What was and what is isn't relevant. Look at the Lingenfelter adjustable in post #26.

Re: Potential Fuel Pressure Regulator Solution
 

OR you could have used the "Dremel" and been done before NOON

You need to remember it's an "engineering sample" that you were afforded the opportunity to "test drive" - that particular one is as it is!!! The likely hood of releasing the FPR and rotating it and compressing again into the cavity I believe creates potential sealing issues. The original Delphi using the snap-ring retention into a formed/rolled cavity I'm quite sure was susceptible to leaking when removed and reinstalled. I've had many 3800's that used that style of FPR.

https://cimg2.ibsrv.net/gimg/www.cor...79076b05f2.jpg

Re: Potential Fuel Pressure Regulator Solution
 

Can put me in line :-D ! not too long ago I started wondering if welding an fittings to the rails and installing my own adjustable unit was the way to go but I have no need for an adjustable unit.. this looks great =D>

Re: Potential Fuel Pressure Regulator Solution
 

Here are photos of the steps I used for adapting the Delphi FP10016 fuel pressure regulator to the original LT5 fuel pressure regulator base:
Attachment 7038
Machining off the old cap

Attachment 7039
Attachment 7040
Failed regulator had a ruptured diaphragm

Attachment 7041
Drilling hole in base for pressing out old hardened valve seat

Attachment 7042
Attachment 7043
Pressing out old valve seat




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Re: Potential Fuel Pressure Regulator Solution
 

http://i540.photobucket.com/albums/g...pspexrsg51.jpg
Base internal machining

http://i540.photobucket.com/albums/g...pscfm1a0dj.jpg
Fabing retainer ring

http://i540.photobucket.com/albums/g...pscb3fkwle.jpg
Threading retainer ring screw holes in base

http://i540.photobucket.com/albums/g...psllwjolzm.jpg
Parts laid out ready for assembly

Re: Potential Fuel Pressure Regulator Solution
 

http://i540.photobucket.com/albums/g...psikzdyriq.jpg
Plug in base installed

http://i540.photobucket.com/albums/g...psfxszsvyi.jpg
O-ring seals installed

http://i540.photobucket.com/albums/g...psohsmjspc.jpg
Regulator inserted in base

http://i540.photobucket.com/albums/g...ps4sgktemf.jpg
Retainer ring attached

http://i540.photobucket.com/albums/g...pst72m6f8w.jpg
Finished!

Re: Potential Fuel Pressure Regulator Solution
 

You need to start an exchange program.. minimize downtime for those interested

Re: Potential Fuel Pressure Regulator Solution
 

That's so Industrial Age chic.:cheers:

Re: Potential Fuel Pressure Regulator Solution
 

Appears somewhat labor intensive Phil. Once the process is sorted out what do you think the time per unit will be? Will you do it yourself or farm it out?
H
:cheers:

Re: Potential Fuel Pressure Regulator Solution
 

My lathe and mill are simple manual machines so set up time between steps consumes more time than I like at my leisurely pace. Was able reduce the time to turn out the retainer ring to 30 min. Rest of the machine work, cleanup, and assembly takes about 2 hours.
Producing several at one time I’m sure would improve efficiency.


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Re: Potential Fuel Pressure Regulator Solution
 

Very nice work Phil!
Rich

Improved Fuel Pressure Regulator Accelerating and on Cruise
 

Fuel Pressure Accelerating and on Cruise.
(Engine in Full Power Setting for all tests) A 1995 ZR-1 with Stock FPR and a 1990 with IFPR were tested with identical results.

https://cimg6.ibsrv.net/gimg/www.cor...915a2b5bd9.jpghttps://cimg2.ibsrv.net/gimg/www.cor...ed552e4baa.jpg

No issues........no stumbling in any gear and very smooth in cruise.

A. Cruising in 1st-5th at speeds up to 60mph resulted in Fuel Pressure of 42 psi except when decelerating pressure dropped to 38 psi.
B. Accelerating in all speeds resulted in Fuel Pressure increasing smoothly to 48 psi while accelerating only then the pressure backed down to 42 psi while cruising.
C. At FULL Throttle the Fuel Pressure spiked at 52 psi in all gears.
[B]D. Cruising at 80 mph in 6th gear resulted in Fuel Pressure stabilized at 43 psi just a tad above idle pressure of 42 psi

This is identical to what BlackZR1 experienced while testing Fuel Pressure while Driving.
Short roundtrip to Fresno (100 miles).....No issues and no stumbling in any gear and very smooth in cruise.
Getting 27mpg - 28mpg in sixth gear going 70mph which was identical to mileage using Stock Unmodified FPR which indicates the IFPR behaves exactly like a Stock FPR that BlackZR1 Tested While Driving with various Throttle Positions.

1990 LT5 and 1995 LT5
https://cimg0.ibsrv.net/gimg/www.cor...2722289df2.jpghttps://cimg0.ibsrv.net/gimg/www.cor...49c30a5349.jpg

Post 281 - The Improved LT5 Fuel Pressure Regulator

Re: Potential Fuel Pressure Regulator Solution
 

Out of curiosity, have u pulled any of the spark plugs?