My new GH Turbo project..

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Re: My new GH Turbo project..

Postby Superscan811 » Mon Dec 12, 2016 8:21 pm

Bit more work completed today. The Low Pressure pump and filter are now installed (just have to secure the filter properly).
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Worked out the throttle linkage, A bit of cutting and welding, along with a few other bits. Still waiting on the ferrules and crimper to arrive..
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The High pressure pump is now mounted under the surge tank.
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I also replaced the crossover pipe.
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Here is why.....
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Bit by bit, it's getting there.


Cheers.
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Re: My new GH Turbo project..

Postby Superscan811 » Tue Dec 13, 2016 10:13 pm

Some new boots for the Scorp..

Image

:D :D :D
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Re: My new GH Turbo project..

Postby Sigmaproject » Wed Dec 14, 2016 11:50 am

None of the images are working for me. They did with the first couple of posts way back. But nothing recent.

Am I the only one ?? :$
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Re: My new GH Turbo project..

Postby Superscan811 » Thu Dec 15, 2016 3:52 am

Sorry people, looks like my router won't forward port 80 for some weird reason. Should be back on line in a few days..


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Re: My new GH Turbo project..

Postby Superscan811 » Sun Dec 18, 2016 9:01 pm

Downgraded the firmware in my modem and hopefully the pics now works..

Let me know if there is still an issue.



Cheers.
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Re: My new GH Turbo project..

Postby Sigmaproject » Sun Dec 18, 2016 9:39 pm

Perfect 8-)
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Re: My new GH Turbo project..

Postby Superscan811 » Sun Dec 18, 2016 10:51 pm

Sigmaproject wrote:Perfect 8-)
Thanks for the heads up Sigmaproject.



Will post a few more pics in the next few days.

Modified the surge tank so it now holds the high pressure fuel pump, as well as the fuel pressure regulator. Also pressure tested the fuel system to 100psi with no issues..

Waiting on several black -6an connectors to arrive to replace the red and blue ones I currently have (too much bling under the bonnet for me)..

Have test fitted the flex fuel (ethanol) sensor as well.

Just have to decide whether to go COP (coil on plug) or FORD wasted spark setup. Favouring the FORD setup because I can use the Dual CDI unit I purchased a while ago.




Cheers.
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Re: My new GH Turbo project..

Postby Superscan811 » Wed Dec 21, 2016 8:34 pm

Well, decided to go with the wasted spark coil setup.
As you might be able to see, the Flex_Fuel sensor has also been mounted to the side of the Fuel Pressure Regulator.

Image

Temporarily cable-tied the fuel lines and spark-plug leads, until the the spreaders arrive.

All there is to do is to mount the MAP sensor, plumb in the pneumatic boost controller, then wire everything up, and of course all the fun of tuning it..



Cheers.
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Re: My new GH Turbo project..

Postby yno26galant » Fri Dec 23, 2016 7:23 pm

Good work scott! :thumpsup:
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Re: My new GH Turbo project..

Postby Superscan811 » Fri Dec 30, 2016 12:22 am

yno26galant wrote:Good work scott! :thumpsup:
Thanks.. Getting there slowly..

Installed the Capacitive Discharge Ignition system and finished plumbing in the MAC valve (pics to come) to control the waste-gate.

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Also, a few more parts arrived. some laser cut, 12mm thick, 316 Stainless exhaust flanges and a heap of Schedule 10 bends..
316 stainless holds up better under Turbo exhaust temperatures than most other stainless steels.

Over $1000 worth of bits, but worth it when you're serious about making a strong and reliable manifold..
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Image

Still waiting on the ferrules to arrive, so I can finish the accelerator cable.

Once again, it's only the wiring that's slowing down this build.
Too many considerations on how to rout the wiring, especially for the sensors, and now that I've decided to keep the A/C, which had been previously disconnected, there is a bit more work required..




Cheers..
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Re: My new GH Turbo project..

Postby Superscan811 » Thu Jan 05, 2017 9:26 pm

Let the wiring begin.....

yno26galant has been a great help with looming the wires in the engine bay and while it took a day just for that, it does look the better for it.
(PS: the below pictures shows my BEFORE effort... :D ).

There's a lot more in the looming than you might first think.
You have to try and rout the high energy wires (ie: for coils, sparkplug leeds, relays, fans, Fast Idle solenoid/stepper etc...) away from your low level inputs(CAS, TPS, MAP, IAT etc...).

If you don't, it can and does interfere with the low level inputs, causing a lot of "unusual" problems.

On all the low level leads I used shielded cable. A lot more expensive, a pain to work with, but hopefully, it should dramatically reduce any chance of those type of problems.


Image

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Still a way to go, but the end is in sight...


Cheers...
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Re: My new GH Turbo project..

Postby Superscan811 » Wed Jan 11, 2017 7:38 pm

All wired up
BUT...

now having an issue with the CDI unit.

It is expecting a 12v signal but the Microsquirt only outputs a 5v signal.

Didn't realise this for a little while but I'm sure the neighbours were amused by the loud explosions they heard.. :$

The main issue, apart from the signal level, is the noise on the line coming out of the ECU....

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The voltage should be a steady 5v but it's between 3.9v and 7v

Put a 10k µf cap on the 5v reference voltage and it cleaned it up a bit, 4.1v to 6v.

Building a small circuit using a 1 farrad super capacitor, a schmitt trigger and a mosfet to
a.clean up the 5v reference voltage.
b. Level shift the 5v output to 12v.

The issue is that the mosfet will invert the output, ie: instead of being a steady 12v with a pulse to 0v signalling the coil to fire, it now will be a steady 0v with a 12v pulse when signalling the coil to fire.

Luckily the ECU can invert the signal and the CDI can trigger on either the positive or negative slope.

If you have made it this far, you are either confused or know a bit about electronics..

The Super capacitor is much like a battery and should hopefully clean up the 5v reference voltage.
The Schmitt Trigger then cleans up the 5v to 0v trigger signal.
The Mosfet then inverts and level changes the trigger signal from 5v-0v to 0v-12v.

Again, there is an issue of propagation delay which according to the IC and mosfet specs, may be as high as 1° at 10k rpm (200µ seconds), but I'll be able to compensate for that in the timing table.

I'll take a few pics tomorrow to better explain what happens.

Cheers.
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Re: My new GH Turbo project..

Postby Superscan811 » Fri Jan 13, 2017 9:04 pm

This is before adding the 1 Farrad Capacitor.
Image
This is after
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The 5v Reference Voltage has been cleaned up considerably.




Now onto cleaning the ECU output.

The BLUE signal is the 5v signal from the ECU.

The RED signal is the 12v output from my little circuit.

Image

Here's a closeup of the transition. There is something funky with the signal going below zero volts before it goes up to 5v.
May be to do with dwell or something else. Not sure..
Image

Glad the output from my circuit has dramatically cleaned up the ignition signal. Had my fingers crossed that it would work.


For those people that are interested, the BLUE signal here is what the Schmitt trigger did with the original ECU signal in the picture above.
The RED signal is the output from the MOSFET
Image

Hope to have it running tomorrow if its not too hot..



Cheers.
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Re: My new GH Turbo project..

Postby mstrrab1992 » Tue Jan 17, 2017 8:52 pm

The only things I understood about those graphs are that they had 2 colors blue and red Haha
All Animals to the Crow: Your not a zoo animal!
Monkey to crow:your just jealous cause noone says "mummy mummy i want to see a crow!"
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Re: My new GH Turbo project..

Postby Sigmaproject » Tue Jan 17, 2017 9:54 pm

what he said :think:
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Re: My new GH Turbo project..

Postby Scorpma82 » Wed Jan 18, 2017 7:51 am

I can't even see the graphs.......saves me scratching my head and feeling a lil ridiculous I guess
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Re: My new GH Turbo project..

Postby Superscan811 » Wed Jan 18, 2017 9:18 am

mstrrab1992 wrote:The only things I understood about those graphs are that they had 2 colors blue and red Haha

Sigmaproject wrote:what he said :think:


Capacitor cleaned up the 5v signal which was fluctuation between 2v and 8v, now between 3v and 7v
Image

Schmitt trigger made a clean 5v "On-Off" signal.
Image

Mosfet changed the "ON-OFF" `signal from 5v to 12v.
Image




The end result is I'm getting a clean signal and at the right voltage to the CDI ignition. :D





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Re: My new GH Turbo project..

Postby Scorpma82 » Wed Jan 18, 2017 10:26 am

So what ur saying is......

Long story short...It's all good :P
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Re: My new GH Turbo project..

Postby mstrrab1992 » Wed Jan 18, 2017 8:57 pm

So everything works how it should, nice :lol:
All Animals to the Crow: Your not a zoo animal!
Monkey to crow:your just jealous cause noone says "mummy mummy i want to see a crow!"
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Re: My new GH Turbo project..

Postby Superscan811 » Wed Jan 18, 2017 10:14 pm

Scorpma82 wrote:So what ur saying is......

Long story short...It's all good :P
Yes.. :D

mstrrab1992 wrote:So everything works how it should, nice :lol:
Took a bit of brain power to figure it all out but yes, the Scorp now starts and runs.

Tuning it is going to be another adventure as I'm working with E85.... :$
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