Fuel Regulator Vacuum line with Zetec Plenum

[Jake Gully]

Where should I attach the vacuum line for the fuel Regulator?

Advice seems to be I should retain this, but unsure if I should port to the plenum or the air filter side of the throttle body.

[J0nnyboi]

all of my vac lines are ported into the plenum

[Jake Gully]

Crimping my 16mm tinned copper lugs to the 16mm cable, using 16mm dies and a hydraulic crimping tool.  Looks like my cable is under spec as even full crimped I can only achieve a loose sliding fit.     The copper core comes in at 5m diameter, which should give around 19mm2, but the very fine strands are compressing - I will have to pack this out with some additional wire...

 

[IanS]

To get cross sectional area you need to take out the air area. 19sq mm is very optimistic because of this.

Normal calculation is π r squared of individual strand times number of strands.

You could try a smaller lug.

I have had poor long term results with packing out coming loose over time, if you do pack out use the same strand diameter and make sure that packing extends past the crimp area.

[Jake Gully]

17 hours ago, IanS said:

To get cross sectional area you need to take out the air area. 19sq mm is very optimistic because of this.

Normal calculation is π r squared of individual strand times number of strands.

You could try a smaller lug.

I have had poor long term results with packing out coming loose over time, if you do pack out use the same strand diameter and make sure that packing extends past the crimp area.

I did some tests today and got some acceptable results by wrapping around the stripped ends.   My next size down in dies is 6mm - might be better off getting some better quality cable..

[Jake Gully]

Back to original subject, I decided to remove the standard fuel regulator as I have an adjustable fuel pressure regulator in my box of parts.   This way I do not need to worry about the vacuum line connector!  I have sourced some direct straight through hose connections for both ends of the fuel rail, which should save a little space and be neater than the original.

 Looking at the fuel pipes around the swirl pot, these were quite badly cracking on the radius bends.   Given that my brother in laws restored Sebring car caught fire and completely burnt out last year, I'm not taking any chances and have ordered replacement for all of the fuel hoses.

 

  

Edited December 2 by Jake Gully
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