I always advise those who install an AI kit to perform basic maintenance to insure their kit doesn’t fail to operate when it’s asked to do so. IMO, the most important consideration with running alky and high boost pressures is that the kit is always able to activate with NO FAILURES being acceptable.

As listed on my DIY Alky page at http://members.cox.net/stevemonroe/AlcoholInjMod.html The following inspections should be performed periodically:

Routine Maintenance:

Monthly - check all hose connections for leaks.

6 Months - Remove up pipe and or nozzle if using the more corrosive methanol & check all components and the inside of the pipe for corrosion & clogging. (up pipe removal not necessary if made of stainless steel material.) Clean parts & wire brush pipe if corrosion is present.

Annually; Replace Fuel Filter if equipped.

Not every Turbo Regal owners’ car will be able to safely run alcohol injection. The added boost pressure will greatly stress the engine internals. Like the Cialis commercial says, consult with your doctor before taking it to be sure it's safe for you. 

Two weeks after installing an AI system on a local GN, the owner called and said his car had a broken crankshaft. He mentioned he already had the motor out so I drove over to inspect the damage. One glance at the crank told me someone had installed one from a non-turbo engine. This crank did not have the stronger rolled fillet radiuses on the rod journals and though it could have lasted for years in normal use, it was not strong enough at the boost levels he was now submitting it to. 

Car #2

The car was in dire need of a rebuild and the higher boost run with his new A/I system the engine spun one of the rod bearings. 

(After the experiences listed above I decided to check this car over to avoid another engine failure.)  

Oil pressure was good but since I had recently purchased a dial indicator and magnetic base I wanted to test it out by measuring the crankshaft endplay which will indicate thrust bearing wear. After the car was raised I removed the torque converter shield and pried against the converter in both directions.  I found that after 130K miles it was well overdue for some repairs. The thrust play was .025" (specs are  .003" to .009") 

I advised this person that he would be wise to correct that problem before adding an Alky kit and turning up the boost.

I go looking for trouble sometimes

This car had 140K but had what looked to be the original fuel injectors. I installed a pressure gage on the fuel rail and asked him to start the engine. While he watched the gage, I went to the rear bumper and unplugged the fuel pump and the car died immediately. The pressure on the gage read 37 lbs when it died so it was obvious that his injectors were completely clogged. Inadequate fuel delivery at high boost is spells trouble. 

OK, these are my actual experiences and by mentioning them here I hope you understand that it’s your responsibility to ensure your car is capable of supporting the demands associated with a 5 to 10 pound increase in boost pressure.

Check the things mentioned above and then if all is OK, I'd then suggest that you test your car with race gas first before you install an AI kit. If you see detonation at anything under 20 psi, your car has issues that need attention. Some causes of early detonation are bad grounds, faulty coil pack or module, weak ECM or corroded pins at the ECM harness and the list goes on from there…

• On board scan tool such as ScanMaster

• Knock Gage such as one from Caspers Electronics (this will give you real time indication of detonation where an ALDL based scantool can report knock by as much as 1.5 seconds after it's occurred.

• Upgraded Fuel Pump with Hotwire kit.

• Tested & known good fuel injectors
• Oil pressure gauge

Now that we’ve covered the mechanical issues, let me mention that initial testing should be done with a non-flammable mix of alky and distilled water. (no greater than 40% Alky to 60% Water) You might not have tightened a clamp somewhere in the plumbing and a full strength alky mix can easily ignite under the hood of a turbocharged car. 

OK That's all I can come up with but if you have anything to contribute to this page feel free to email it to me. Thanks for reading my ideas on how to run Alky safely! Good luck with your Alky system.