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540 EFI Build-up Thread

hadleycat said:
I am currently looking into options for upgrading my fuel system on my Procharged 502 mag. One of the items that looks promising is the Holley controller such as you working with.

Build looks great! Good luck and hope to see you on the water soon.
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The best thing you can do is do away with the merc EFI(sell it complete) and do a complete aftermarket one, by the time you deal with all the B/S to get the merc stuff to work decent you would be farther ahead with a decent intake, rails injectors, etc...
 
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Does anybody run FAST XFI stuff? The only reason I ask is that i have some experience with their product from back in my mustang days. I know its kinda pricey, but I loved tuning with it. How much is the Holley stuff going for?
 
I talked to fast, holley, accel, big stuff, a while back, they all do some nice stuff, when I was setting up our LS drag radial car, none gave me the warm and fuzzy and all had reason my setup would not work, but did the megasquirt for less than 1/2 of any of them wanted and worked great, so also use one on the boat with our EFI setup, now that was over 3 years ago and they do in fact have all the stuff to run LS coils etc, just the cost over 2k seemed way high, we are now a mega squirt dealer and can tell you their stuff works great...BUT there is no pick up the phone tech support like some of the others...
 
The FAST unit is not potted/sealed like the Holley unit is for marine use. FAST does make an XFI unit that is marine rated and sealed, but like everything else marine it is significantly more expensive. The base XFi system is also pricier than the comparable Holley setup. From what I hear, the FAST software is not as user friendly nor as quick learning as the Holley. Both are great units though.

The price is high with any self tuning EFI system but the savings comes in with reduced tuning/dyno farting around. Also whatever mods you want to do down the road or put it on a whole different engine, you wouldn't need to buy much of anything. With EFI most of the expense is upfront in the initial component purchase. When comparing to carbs, to have a pro setup a boost referenced carb, it is almost as much and will still never be perfect in EVERY rpm range whereas EFI has that ability.

As far as Hadley's setup, I would go with the Edelbrock Pro-Flo XT manifold and a 92-105 mm throttle body. That manifold has all sensor provisions, already machined for injectors, and has available pre made fuel rails. In the end, it would be much cheaper than going with a carb intake and 4150 4 barrel throttle body and carb hat for procharger. The LS2 flange throttle body that the Pro-Flo accepts are very inexpensive and readily available compared to 4 barrel throttle bodies. It would also allow you to easily plumb the boost tube right to the throttle body with no special adapters and would give nice straight flow into the plenum. That is what I would do if I had a procharger and wanted to ditch MEFI.
 
More Progress. The chevy dealership gave me the wrong oil bypass valve so i cant install block adapter and oil cooler until i get the right one under there. And the plug i bought co convert to full flow doesnt fit inside the valve like it is supposed to either. Anyone know the easy way to plug this hole off for full oil flow?

Got the thremostat housing, crossover, and rear water port dumps on:
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Manifolds and ls ignition coils mounted. I think that turned out nice:
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Starting to look like something now:
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Looking good Ron, you might beat me back to the water. One of mine is at the machine shop right now
 
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Back to the drawing board today. My fuel pump and cooler bracket goes to scrap pile. Interferes with sea pump. Didnt think about that when i was mocking it up. Originally it mounted on other side of block but my oil cooler is so big that is the only spot it fits. Sooooo, time ti get creative. I already found a good new location for fuel cooler.
 
More Progress, Got most of the plumbing done. Good lord there are a lot of hoses! Of course I am about 6" short on my hose sleeving to finish one riser tube. I was able to relocate the fuel cooler easily enough but have yet to figure out the fuel pumps new location. That is tonight's project. Ran out of hose clamps and need a couple pipe nipples to splice water hoses where I had to make my own shapes to fit. Other than that, everything is shaping up. Still waiting on EFI. Also, the Chevy dealership gave me the wrong bypass valve and the new one wont be here till tomorrow then I will be able to prime the oil system.

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All of the plumbing is pretty much done now. Finally got the right oil bypass valve yesterday and finished plumbing up the oil cooler. The plumbing isn't as neat as I would have liked but room was very limited and I can only bend 5/8" hose so far before it starts to kink off. I also installed a cheap mechanical oil pressure gauge on the engine for redundancy and ability to read pressure when in compartment and priming the system. Also, here are some finished pics of the exhaust risers and pyrometer/oxygen sensor ports. I hit the welds and bungs with a small buffing wheel in the cordless drill and Blue Magic metal polish. That stuff is great on stainless but a little too harsh for a mirror shine on aluminum. They polished up easier than I thought they would.

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Half of the EFI components have shipped out to me and the other half are anticipated next week. Unfortunately I don't think I will be making the Rally but I will probably be running that weekend. Just wont be soon enough to test, tune, and prepare truck and trailer for that long of a journey. Just not enough time in a day anymore.
 
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