But it was blindfully obvious that the big ol hoop of a rail tie just wasn't gonna fit. So I ordered 2 90 degree fittings to do the job. The rail tie line is much better now.
I had a hell of a time pressure testing the fuel rails. They have to seal completely - that goes without saying. The metal is thin on these rails and it was very difficult to do. I'll say I have much more of a clue about voltage settings and wire speed than I did before pressure sealing these rails. Everything I welded before that was cake - short shifter, motor mount for the nephews go-cart, stupid little things. The rail has to be leak-free which turned out to be flat out not easy as a newb welder.
I used my son's 1/2 gal bubble bottle to test the seal.
Plug in the shitty test injectors, dab a little bubble-stuff on the weld area, plug one end and blow into the other. Bigger leaks show up as big bubble fests. Pinholes show up as foam.
Anyways, I start in on the primary rail(stock injector rail), and it turned into a nightmare. I worked on that rail for 2 days before I finally figured out a good setting for the welder - rewelding, regrinding, pressure testing, rewelding, regrinding, pressure testing, endlessly. I actually blew through the rail twice. The first time it was so bad I had to make a patch to cover the hole. But after I figured out the right settings - the second rail only took about a half hour to seal up tight.
Just finished painting them last night. I think this thing is finally ready to install.
#51803, "RE: 8-inj manifold ready to install." In response to Reply # 0
That looks like an incredibly professional install! i wish i knew how to weld. my dad is really good at it, but refuses to show me how to. www.TeamKLR.com 1997 Silver RS Wiseco 8.8:1 Pistons(back to low compression!) Eagle Rods T3/T4 Turbo Custom FMIC Greddy Exhaust 440's Most current 1/8th mile time: 8.3@90mph 2.015 60'(Nitto Drag radials, i suck)
#53969, "8-inj manifold REALLY ready to install." In response to Reply # 0
Long time since I posted this, but a few things have happened and wanted to give another update.
I suppose the first bit of news is that I finally got the rails hooked up to my air compressor for a descent high pressure test. It turned out that I had a bunch of pinhole leaks still. Smaller than I could find by just blowing into it. So I ended up using JBWeld epoxy to seal it up. They're both holding solid now.
After I got the rails sealed up, I went ahead and started testing the assembled manifold. Lemme just say that I have no idea how many times I tried to get it...lots. I never got the damn thing to seal at the compression fittings. I tried different length tubing, different assembly orders, pretty much every single way that it could possible be assebled I tried. Thought about it for a while and came to the conclusion that this particular area was just not a good place to be using compression fittings. See picture:
After seemingly endless attempts of compression fitting this rail tie line together with NO luck, I decided to just use ss hose. I pressure tested the assebmled manifold to 40psi with the new hose in place - no leaks.
I'm using 2 Russell full flow swivel 90 degree fittings and -8AN hose.
You can see the grey parts on the rail are where I epoxied it.
It really is ready to install this time except maybe for some new paint on the rails, you can kind of tell I was working with them quite a bit...but mechanically its ready.
#53988, "RE: 8-inj manifold REALLY ready to install." In response to Reply # 4
Hay jim looks good i painted my rails almost the same color just chyrsler blue same as the motor. Looks good and thanks for all the help with every thing.
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i wish i knew how to weld. my dad is really good at it, but refuses to show me how to. 
