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Fuel Tuner Case + Recirculation Valve Adapter

Both of these projects are tied in with the turbo conversion on my Hyundai Tiburon. The first part I will be making is the case for my fuel tuner and then the second part will be a valve adapter.

 

Fuel Tuner Case

Here is a picture of the fuel tuner, it is important that it is put in a case to stop foreign debris from shorting terminals. The fuel tuner will be accessible behind the glove box in my car where I have also situated the ECU. I must be able to get to the tuner just incase I need to disconnect it, this is if my MAF sensor fails or I get a leak between the MAF and the manifold. The purpose of the fuel tuner is to control an extra set of injectors, it means the stock fuel system can work normally.

 

3D Printed Fuel Tuner Case3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

 

The first step was to make an outline of the outside of the case, this was done from measuring the circuit board.

 

3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The outline was then extruded.

 

3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The inside of the case is to be cut. Since there is a lot of space it is a good idea to hold the board in place, I chose to go with some rails.

 

3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The profile was then extruded cut, here you can see the board has some tracks to slide in place.

 

3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

The file was then imported for the 3D printing software to generate some g-code.

 

3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

 

 

I chose to print the case in PETG just simply because it's nice stuff, I chose red because I don't use much of it. Unfortunately the first print was a disaster, I think I printed it too fast. I also heated the bed up too much to remove the part which resulted in me wrecking it. I sometimes find the programs to be a little erratic in which they produce a spider web, the idea to prevent this is to retract the filament but that can have the opposite effect and leave little holes.

 

3D Printed Fuel Tuner Case3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

 

The second print was run a little slower but I also increased the layer height. I still got quite a bit of spider webbing on the inside but overall it came out a lot better. Here you can see my circuit board fit in the box snuggly but still easy enough to remove if I need to program it.

 

3D Printed Fuel Tuner Case3D Printed Fuel Tuner Case

 

 

 

 

 

 

 

 

 

 

 

 

Recirculation Valve Adapter

The recirculation valve is used to release the pressure after a turbo when the throttle is closed, by venting the air it prevents pressure spikes which wear turbo bearings and can also pop apart piping. I originally didn't bother with this on my car and allowed the air to surge back through the turbo, it sounded cool but actually hurt performance. Eventually my MAF sensor blew off the manifold and made the car almost impossible to drive. The recirculation valve is normally fed back to the inlet to reuse the air, however I will just vent it to atmosphere since it sounds better. The picture below shows approximately where I will place the valve.

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Here is a pipe adapter which was originally used to connect the recirculation valve to the turbo pipe work. My goal is to make some way of bonding this to my turbo pipe work.

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

When I start drawings I always like to design them in a cross-section view. The diameter of the pipe adapter is 27mm, after 3D printing the part it will shrink slightly which means that I will get a tight fit.

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The drawing is then revolved around an axis in order to make it solid.

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

This part will butt against the pipe work below my MAF sensor, the outer diameter is 82mm.

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The circle is then extrude cut in both directions, easy as that !

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The part was loaded into my 3D printing software.

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

Since the bottom of the part was hollow I would need to add some support, here shows a section cut of the supporting layers.

 

3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I chose to print the part in polycarbonate due to it's resilience to the heat present in an engine bay, this material is not petroleum proof however. Since I will be using epoxy to bond all of the parts together it would not matter because I would coat all of the surfaces and therefore no polycarbonate would be able to dissolve. Another beauty with 3D printing is that most of the parts will be porous, it is highly likely that the epoxy will soak into the part and harden it further.

 

3D Printed Recirculation Valve Adapter3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

Here you can see the part worked out perfect.

 

3D Printed Recirculation Valve Adapter3D Printed Recirculation Valve Adapter

 

 

 

 

 

 

 

 

 

 

 

 

If you would like to see what project this went into then check out the turbo build on my Hyundai Tiburon, otherwise check out the rest of my projects.

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Hello, if you have enjoyed reading this project, have taken an interest in another or want me to progress one further then please consider donating or even sponsoring a small amount every month, for more information on why you may like to help me out then follow the sponsor link to the left. Otherwise you can donate any amount with the link below, thank you!