Some progress...
I've made some changes, which basically invalidate the cost spreadsheets that I started on the first page.
First, with this Ford throttle body, there is no need for the Idle Air Control (IAC) stepper motor control that comes with the MegaSquirt 2. The first board I bought was a V3.0 model, which is also not needed for this conversion. So, I purchased a MS1 with the V2.2 board, which can run the MS 1 Extra code in MSnS (MegaSquirt N' Spark) mode. The injectors in this TB are low impedance, but not super low (2.5 ohms) so I'm going to run without the flyback board
http://www.megamanual.com/v22manual/minj.htm#fb and add 4 ohms of resistance
http://www.megamanual.com/v22manual/minj.htm#injresist to each injector circuit. This will bring me into the constant 200 mA per injector range that the V2.2 board without the flyback circuit can handle. And I have the resistors in my junk box. Should be ok ... we'll see. If I need the flyback board, I can build it from my junk box plus about $6 in parts so that's not an issue.
The MS1/V2.2 kit is $169 from DIY Auto Tune
http://www.diyautotune.com/catalog/mega ... p-128.html - they are the only USA supplier that I know of. The MS2/V3.0 kit is $279, a significant savings. (The MS2/V3.0 board will be used on my CJ-6). You can also buy a minimal kit with the circuit board, CPU, and MAP sensor for $125. I started to add up all the extra parts you would need to use the minimal kit, and it easily went over the $44 difference. So the full kit seems like a no-brainer.
I also determined that the fuel pump I was going to use won't be adequate. Originally I was going to put the Bosch 69238 fuel pump in the gas tank, but that pump is only rated for 43 psi (3 bar). That's enough for the GM throttle body which operates at about 15 psi, but it's not enough for the Ford CFI pressure regulator, whose set point is 39 psi. It might be ok, but I'd have no opportunity to increase my fuel pressure if I needed to. So I bought an Airtex E2000 fuel pump, an external pump that is the factory pump for some Ford cars and trucks. Airtex rates this pump at 70-95 psi, which should be adequate (Amazon, $63.23
http://www.amazon.com/gp/product/B000C1 ... UTF8&psc=1 - I have Prime so no shipping, otherwise RockAuto is cheaper). I also bought a Mann MF1002 filter to go with the pump (Rock Auto
http://www.rockauto.com/catalog/moreinfo.php?pk=2265212 $3.41). Both of these use the Ford barb fitting which are meant for nylon line (Dorman 800-080
http://www.rockauto.com/catalog/moreinfo.php?pk=4391574 at $1.87/pair close-out). You can get these at the junk yard easily ... they work fine with the rubber EFI hose.
Normally I would have looked for the pump and filter at the junkyard, but we have lots of snow right now, and I probably won't be able to go on a junkyard expedition until April... certainly I won't see my lawn until April, the way things are going now.
I grafted the Mustang air cleaner base to the original 258 air cleaner. Here are a couple of pictures of that -
Soldering works pretty well for this. The graft needs to be a little off-center for clearance with the wiper motor. You can see that here -
I will make a new air cleaner stud with a jog, but I need to buy some steel rod. No opportunity to go to the Home Center yet, due to the weather. The alternative would be to drill a new hole in the air cleaner lid, but that seems like too much of a hack.
A little clean-up and paint and it'll look like a factory installation.