Ned Posted November 15, 2015 Author Share Posted November 15, 2015 Had a quiet weekend this weekend. Did some RC flying with Cam, Jess and Jerm on Saturday morning, and then motivation dwindles quickly, and Sun afternoon i went to my sisters BBQ thing in Hamilton. Got SOME stuff done though! did some CAD work (Cardboard Aided Design) for a hall effect trigger wheel setup this is as far as i got before i broke my angle grinder Cam having a go at soldering up some fuel lines turned out mint! shit photo though, sorry... so the old return line fits very nicely inside the 5/16ths line i'm now running as feed and return, so soldered it all together and seems pretty legit to me! Also went to Zebra and picked up some new bits and bobs but wont bother posting photos of that, but got the m,issing bracket for the throttle, IAT sensor, bracket and gas filter for MAP sensor and a throttle bracket than might let me reverse mount the throttle cable as that would look much much better! 2 Quote Link to comment Share on other sites More sharing options...
Popular Post Ned Posted November 23, 2015 Author Popular Post Share Posted November 23, 2015 Not a super exciting update picture wise, but heres what happened over the weekend some cool dude (cam) made me a lush bracket to mount a new coil and little tiny igniter right onto the block, next to the dizzy. He painted it after and looks the business for sure! i made cam angry when i put the pretty new thing in the dirty old thing without cleaning it and making it look good while it was out i didnt take a photo of the end result because i threw my toys big time working on bloody hard line! getting hard line right is a PITA and i dont ever wanna do it again! but here's a token pic anyway... thats before final bend and flare on the end, and also before the return line was added. Put in new 5/16 steel hard lines for feed and return. Fuel system is now the pretty TTT made thing with 1/2" feed and 5/16 return with AN fittings. 1/2" goes through soft line and filter to the back end of a Bosch 044 (china) and comes out as 5/16, which then goes to hard line to the front of the car to another filter and through the standard fuel rail and reg with a new pressure sensor. From there back through the standard return line to the firewall, where we changed the hose to go to 5/16 again and runs through a new hard line back to the tank. we were worried about the 044 blowing the reg off the rail, or at least flowing much more than it would handle, and we'd have to slow the pump down somehow. Already thought up ideas of PWM controlling it to limit flow, or making a cool constant current supply to limit pressure, or extra reg... so thats why we installed the pressure sensor, so we could keep an eye on it. We finished the fuel system yesterday, put in some fuel, multimeter on the sensor and hooked the pump up to the battery and crossed our finders. Bloody works! no leaks, legit stable pressure (46.25PSI) so that was a very happy moment after messing around with it for so long and being worried about the dumb decision i made to buy a china 044 (not because china, but because 044 way over spec's a little 7K) after that we made a start on the wiring. Got supervised by Ed and by Houdini. More tonight and tomorrow and then maybe i'll be able to fire it up before burger boes on Wednesday!!! Some bad news though, wont be running it on my own hardware for the next little while, because the code (FreeEMS) isnt good enough to handle the factory trigger setup, so i'll have to write my own code to do that and there isnt enough time for that before burger boes, so going for a borrowed microsquirt to get it on the road and swap it over to my own thing later... good thing its the same pinout 10 Quote Link to comment Share on other sites More sharing options...
Ned Posted November 23, 2015 Author Share Posted November 23, 2015 i need to take more photos... Some cool cat (slacker.cam) tidied up some of the standard wiring yesterday because there were a bunch of no longer used bits in there etc as you can probably tell, all the super lush shit generally gets done by Cam and im the dick in the background complaining and doing sub-par work 6 Quote Link to comment Share on other sites More sharing options...
Popular Post Ned Posted November 25, 2015 Author Popular Post Share Posted November 25, 2015 wow, so much tired, so much great though... so not very interesting things first, i mounted the wideband the other day and sacrificed some of my finger in the process Wiring was well underway Monday night and put a big dent into it anyway. Most the sensors had wires on them pretty quick. The tefzel is nice and small and awesome, but a little harder to work with. The stripping of the cable is a bit harder. The insulation is quite hard and slippery, but with good crimpers, life is good really. I normally just post photos with a description, but i might waffle on a bit more because it might interest 1 or 2 other people. Photo skimmers can just ignore text To do my wiring, i made a 'golden sample' of how much wire i needed from the firewall hole to the ECU (ECU is further than fuse box, so if it reaches ECU it can reach fuse box) and then i would just havce to measure the length needed for the sensor wires to the hole in the firewall and add the length of the golden sample. I started by soldering all the sensor plugs to new leads and making the ignition lead for the ignitor/coil/tacho feed etc. I knew i was going to run the TPS, IAT, IAC, CLT and Fuel pressure all together, so i put a bit of small braid on the plug end of all of them and then some bigged braid over the whole lot before feeding it through the firewall hole. Then the rest was the same, but some leads didnt get bundled up and just ran small braid over the whole line. While i wired stuff, Cam was trying to make the microsquirt rookie gave him behave. The board was well toast and the VR conditioning hardware on the board was toast. i had no idea what that above statement meant a year ago, so let me waffle on again and expand. You guys let me know if i can stop with the waffle in the discussion thread... VR is a variable reluctance sensor. It basically creates a voltage when a tooth comes near it and the voltage goes away again when the tooth goes away. This is how the ECU knows where the engine is. The problem is that VR sensors use AC, and the ECU needs to get its information in DC, so you have some conditioning circuitry that converts it. What they use is a zero crossing detector. When the tooth passes the sensor, the voltage first goes up, and then goes down. When it goes down, it actually goes to negative volts. The point where it goes negative is the point you want to detect wit the zero crossing detection circuit (where it crosses zero volts, aka ground) this is what it looks like and here we have cam spinning a spare dizzy by hand, with it connected to the circuit he made up this is what the 'workbench' looked like at the time and here you can see the VR sensor AC signal in yellow, and the nice square DC signal in blue sorry about the shit photo here so i put a smile on my phase and went back to wiring while cam figured out why it was quite buggy and kept failing and freezing once he actually pu the signal into the ECU... Got some wire coming into the cabin! finally! and pretty braided wire in the engine bay some early morning sun from the next day. Engine bay wiring was done, ready to tackle the inside wiring! it's not actually THAT many wires... thing with was ~35 wires? i labled them all with a label maker that prints on heat shrink! so so good this wiring shouldnt change, but for fault finding, this is def the way to go i think! Cam asked a couple times "did you plug xyz sensor in the right place, it doesnt work...?" and if i hadnt labeled them, i'd be shit out of luck if i tried to trace it... Its a label maker me and cam went 1/2s in. Its a DYMO Rhino 4200 for those interested. Theres one on trademe for $629, but america has them for $60 here. We even got ours on a 1/2 off sale or something? cost like $40 NZ at the time plkus shipping. The problem is the heat shrink isnt cheap. ~$65 for 1.5 meters. Plug is going on! I actually had an issue with the plug, and thats that when i ran 2 or 3 cables into the crimp terminal ,it wasnt too happy about the connector closing. The connector had a little clip plate that slides off, and lets you put the pins in place. Once they are all in place, you clip it back in and it locks the pins. If the pins arent seated right, the clippy in bit wont clip back in, so i extended a bunch of the double and tipple cables by an inch or so and plugged them all in with a single wire in the crimp terminals and was sweet. Made the wiring much more yuck though because the lengths werent all the same anymore and tangled a few things when i plugged everything in for the second time. Meh. Then it was time to see if it would work! tested a few sensors and it all failed. Turns out the 5V signal for the MAP, TPS and fuel pressure wasnt working so we jumper wired that on the ECU too. Tested some more and we had spark and could hear injectors and fuel pump control worked, wideband worked, idle control didnt, IAT didnt, battery voltage measurement didnt, god knows what else didnt, but this did; so after that, we threw all the rubbish on the floor and drove it to monthly meet! Cam lives 20-30 min from the monthly meet, and only 2 streets from the motorway. before we left we noticed the car was mega rich, so cam leaned it out a bit and after a little tinkering realised the ECU was adding HEAPS more fuel because it though the battery was low, so the injectors would need more on time to deliver the fuel, but the battery voltage was fine, so it over fueled. Disabled that, and off we went! Its running ok, but not fantastic, but we get it 200 meters down the road until it starts to cough and splutter... great! car dies so we have a look around for why. Cam on the laptop and me IRL. ignitor was roasting hot! not good. cam looked around trying to see why for a while and i grabbed the IR temp measurement tool and a good 5 min after turniong off the car, it was still at 100 deg! so that sure did get hot! Turns out the battery voltage thing wasnt disabled for the dwell adjust and the ecu was over dwelling by like 1000000000%. Cam hit some keys and off we went. Idle was hard to control and was still running silly, but a choice had to be made 100m down the road; do we go on the motorway or not? go big or go home right? lets motorway it! Problem is that that entire stretch of motorway is being widened and there is no shoulder to pull over on if the car died and it was 7pm, and there is still plenty of traffic at that time having to cross the city. Car made it though, in 1 piece and after burger boes made it all the way home to Cams again too! Some pics Navneal took 23 Quote Link to comment Share on other sites More sharing options...
Popular Post Ned Posted July 11, 2019 Author Popular Post Share Posted July 11, 2019 wow. Been a while! this car still goes, and is actually the only car i own these days... Since the last updates, it has run 2 or 3 OS Drag Days, where it would just do run after run after run! like 30 runs in a day, and is just sooo much fun! slow... but fun! It has also been on a number of fun trips that im going to share with you now, and has proven to be a capable trow beast! BUT It also has done a lot of not-driving. 2 diffs and 2 gearboxes in 12 months? so we're pretty good friends with AA (plus) and theres been a fair bit of this But, it's all worth it! because days like this are hard to beat! We have some plans though... Great plans! And the 'final' piece fell into place today.... I have in my garage a shortened Hilux LSD with disk brakes, buying, today, a K-T bell housing, and in slackercams shed is a T50 with my name on it... Plan is to install all of that before drag day, and hopefully i wont smash all my driveline gear again which is great, because then i have no excuse to do other things to this car maybe one day... as i never wanted to do more mods as i was breaking diffs and gearbags already, so didnt wanna put any more power into it... Plus, i kinda like how fast/slow it is... its the right amount of fast you can beat on it on a daily drive around the block, and not get into too much trouble! but at the same time, triple digit HP numbers would be nice... Anyway, thats what we're up to. This car is my ONLY car, so that makes mods more fun... but i live in Taupo now, so cars are optional... plus partner has a car and i have a scooter, so she'll be right. 24 Quote Link to comment Share on other sites More sharing options...
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