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 Post subject: Re: FrankenFerrari
PostPosted: Mon Jan 11, 2016 11:29 am 
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The wiring has begun...which starts with removing the harness I started building 8 years ago for the V8 and trying to remember what everything was in the mess I created under the dash :shock:

The old harness is all aircraft grade wire so I carefully removed it rather than cutting it out to save the wire for future use.


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 Post subject: Re: FrankenFerrari
PostPosted: Mon Jan 11, 2016 3:57 pm 
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That's something I hate about these modern cars. My Formula Ford has a total of about 6 wires. Good luck, making a clean harness will pay off later.


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 Post subject: Re: FrankenFerrari
PostPosted: Mon Jan 11, 2016 8:58 pm 
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yeah....I'm a long long way from 6 wires

coils = 48 wires+relayx2+ fuse x2
injectors = 24 wires+ relay+ fuse
TPSx2 = 6 wire
Throttle pedal x 2 = 6 wires
Throttle actuator = 2 wires + external driver+ realy+fuse
MAP = 3 wires
MAP per cylinder - 18 wires+ CAN AN expander
Baro = 3 wires
CLT = 2 wires
IAT = 2 wires
Fuel Temp = 2 wire
Fuel Pres = wires
Fuel pump = 2 wires+relay+fuse
Coolant fan = 2 wires+ relay+ fuse
WBO2x2 = 18 wires+fuse+ external controllerx2
NBO2x4 = 16 wires+relay+fuse

and I'm sure I'm forgetting something....... :cry:

I'll need to make a pigtail to let me test o5e too


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 Post subject: Re: FrankenFerrari
PostPosted: Tue Jan 12, 2016 9:40 am 
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mk e wrote:

and I'm sure I'm forgetting something....... :cry:


Crank trigger - 2 wires
cam trigger = 2 wires
Front wheel speed x 2 = 6 wires
rear axle speed = 2 wires
Coolant gauge (feed by ECU) = 1 wire
ECU power and ground...12 wires

I think that's it now....about 182 wires :o


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 Post subject: Re: FrankenFerrari
PostPosted: Wed Jan 13, 2016 2:59 pm 
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I got started with the wires.....a few more days.


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 Post subject: Re: FrankenFerrari
PostPosted: Thu Jan 14, 2016 10:54 am 
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I starting to work on grounding. I'm not sure how crazy I want to get with this. On the old setup I just connected to the ground in the factor harness and called it a day....but I was pulling a lot more power than stock and I knew that was probably not the best setup but I did it anyway because it was easy.

Now I'm pulling more power again and thinking I really need a better grounding plan. I see instruction on some ECUs that call for stuff like "run THREE 16g wires DIRECTLY TO THE BATTERY" which generally means they did a terrible job sorting out grounds in the ECU itself but that's not my concern. I'm concerned mainly with the very short injector pulses my huge injectors will be using and that controlling them means knowing exactly what voltage they are seeing.

OEMs usually do a "star" grounding setup with a big ground fanning out to main points on the engine and chassis and that is my general plan. It's obviously more work but I really don't want to be chasing mystery issues that poor grounding creates. I'm thinking I'll pick up 6-12 points around the engine bay and trunk as well as tying into the stock ground line and that should be about as good as it can be.

I also realized I hadn't really picked mounting locations for some stuff so I'm sorting though that so I know where to run the wires.

Then there is the ECU. I've spent some time using the engine simulator to create the base fuel and spark tuning. The fuel table is 3-d but the data I'm going to starting with is 2-d because I define load as MAP/baro *100 and VE as what the engine is doing compared to what is possible under current conditions.... and that should mostly collapse fuel to a 2-d item.....mostly so the table is still 3-d if I need it. So I pulled the VE numbers out of the simulator for WOT and filled in the table.....it if's close on estimated hp and I think it is, I'll be close on VE tuning. Then I set the mixture to 0.9 lambda (about 13:1 AFR) everywhere so I should have enough fuel everywhere but it shouldn't be too rich to run anywhere even is there 30% error in my VE guesses. I also set the injection end time to 360 so for now it ends about the time intake begins, not what I what long term for at least the full power fuel timing but this tends to be a stable safe starting point so good for now.

Then spark. I always like spark locked at idle and cranking...but I don't really know how much vacuum this engine is going to pull so I don't really know how to scale the spark. I'm guessing it will pull 8-10in/hg vacuum which is 25-35kPa vacuum, so I based the table on idle at 70kPa (100-30) and we'll see how that works. Its easy to just change the axis values once I see where it actually idles. And I'm also assuming that I can do idle control with the throttle...but I may end up needing to lock the throttle and use timing for idle control...another we'll see. simulator.

I was amazed how close the simulator was to the stock QV timing . QV is 32 degrees at high rpm....the sim is telling me 33 and I have a slightly bigger combustion chamber so it seemed right so for full power I pulled the numbers straight in as the base line. Ferrari didn't add really any addition advance under vacuum but I've always found it helps especially if the mixture is leanish under vacuum which I usually do so I through some more advance into the base table.

Then I added a tuning screen with pretty much ALL the gauges so I have a master panel to watch everything that's happening

Getting close now.


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 Post subject: Re: FrankenFerrari
PostPosted: Fri Jan 29, 2016 2:52 pm 
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Still working on wires...yuk!

I did decide to add some color to the tuning screens.

There's a new engienlab version out V97 (all AEM stuff is V96 based)...I'm trying to decide if I want to mess with it right now or stick to V96 until I'm up and running.......I'm not sure what all changed and what all I'll need to change in my model which I thin is ready to go to live testing and I don't really want to mess it up.


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 Post subject: Re: FrankenFerrari
PostPosted: Fri Jan 29, 2016 7:10 pm 
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mk e wrote:
There's a new engienlab version out V97 (all AEM stuff is V96 based)...I'm trying to decide if I want to mess with it right now or stick to V96 until I'm up and running.......I'm not sure what all changed and what all I'll need to change in my model which I thin is ready to go to live testing and I don't really want to mess it up.


It turns out I was scared for nothing.....it took me about an hour to update my model to V97 and it seems to be working correctly again. If nothing else the fuel flow that the model is calculating matches what dynomation5 (engine sim I use) says the engine needs so it looks right.

I need to figure out what else is new in this version. They were talking about adding states which the last version didn't exactly have......you could do them but not more than 6 and not formally. Not sure they added it though.


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 Post subject: Re: FrankenFerrari
PostPosted: Sat Jan 30, 2016 6:48 pm 
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A long day playing with wires. The harness is mostly sleeved, just the front part remains and I want to put the harness in before doing that part. I've also got about 1/2 the engine bay connectors installed on the harness.....another 6-8 hours and I should be ready to put the harness in the car for real


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 Post subject: Re: FrankenFerrari
PostPosted: Tue Feb 02, 2016 2:07 pm 
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Still wiring.......

Last night I added the 4 NBO2 connectors.

Remaining connectors in the engine bay are:
12 coil connectors, 4 wires each
Fuel pressure, 3 wires
Fuel Temp, 2 wire
Throttle actuator, 2 wires
TPS 2, 3 wire
Splice a connector into the stock speedo wires, 2 wires

This will push into the weekend now that I really look at what's left. Then the fuses, relays, and the ECU itself will be at least another week I guess.


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 Post subject: Re: FrankenFerrari
PostPosted: Wed Feb 24, 2016 1:15 pm 
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This is getting really close now. The ECU is connected and All the sensors are reading correctly, the electronic throttle is working, I have a base tune roughed in.

I need to make the plug wires so I can check the base timing, install the rear headers and the cross-over between the 2 fuel tanks, add coolant and I think I can try the engine. A week maybe before I know something one way or the other.

I did (re)learn in the testing that division by zero is bad...... all denominators in my model are tested and forced non-zero before a division happens now.


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 Post subject: Re: FrankenFerrari
PostPosted: Fri Feb 26, 2016 12:57 pm 
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Plug wires are done, base timing set, the timing the software commands is at the plug.

Hopefully it will fire up tomorrow.....


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 Post subject: Re: FrankenFerrari
PostPosted: Sat Feb 27, 2016 2:46 am 
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That's very exciting :D I'll keep my fingers crossed.


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 Post subject: Re: FrankenFerrari
PostPosted: Sat Feb 27, 2016 2:57 pm 
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Horizenjob wrote:
That's very exciting :D I'll keep my fingers crossed.


Unfortunately it didn't go as planned. The rear head needs to come off to figure why the Cyl 4 runner is filled with coolant.


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 Post subject: Re: FrankenFerrari
PostPosted: Wed Mar 09, 2016 4:21 pm 
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The hole is fixed.....hopefully Saturday will be start the engine take 2


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 Post subject: Re: FrankenFerrari
PostPosted: Mon Apr 25, 2016 8:08 am 
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A little update.....I found more leaks and after the R&R on the rear head there was no compression in the rear cylinders and the fronts weren't really what I expected....and the leak-down test was awful so the engine is out and on the bench. :(

Carelessness during the head r&r-install lead to bent exhaust vales, new valves are on order to replace these. I also found a bunch of mildly tweak valves everywhere else which I was able to straighten except 2 intakes that were scrap so replacements for those are on order....so 14 valves total at $28 each :shock: Remember I bought these as blanks so I'll need to cut the stems to length and put in the keeper grooves

Then the leaks...I bought some rubber and aluminum to make leak test fixtures that will let me pressurize the head and still see into the ports. I'm also going to make a fixture to let me lead-down test the valves before I install the heads so I'll know all is right there.

Then, I found a place about 30 minutes away with an engine dyno and a full fab shop that is very willing to help get my engine on their dyno so the next run attempt will most likely be on the dyno where it's way easier to work on the engine should it be requires.

Spring yard work has kept me busy the past few weeks so I haven't made much progress but I do have a plan. I think 3-4 weeks of work and it will be ready to take to the dyno.


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 Post subject: Re: FrankenFerrari
PostPosted: Fri Mar 10, 2017 3:17 pm 
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A quick update.

The engine now mostly runs. I set the shop on fire on first run day and got kicked out to the actual garage but cleanup has taken a lot of time and I have to build a new DETACHED shop this spring so car time has been limited.

Limited time means limited program but I've had it running 1/2 dozen times for a few minutes each before shutting down to fix something. The ECU code (in the enginelab ECU) seems to be working pretty well but I continue to tweek it.

My thought is that once its working well I'll start re-writing the o5e code to work the same way..although I no longer have Franken ECUparts and Rob has vanished so I'll need to buy new parts....but hopefully by fal or winter I'll be back to o5e work


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 Post subject: Re: FrankenFerrari
PostPosted: Thu Jun 22, 2017 9:42 pm 
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Running! ......and it only took me 9 frikin years

https://youtu.be/Pz-Oj4xJi2w

Tonight it was running without any backfiring or any other drama with 1.0ish lambda on both banks idle redline. Time to drink.


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 Post subject: Re: FrankenFerrari
PostPosted: Fri Jul 14, 2017 11:06 am 
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mk e wrote:
Running! ......and it only took me 9 frikin years

https://youtu.be/Pz-Oj4xJi2w

Tonight it was running without any backfiring or any other drama with 1.0ish lambda on both banks idle redline. Time to drink.

Progress. :)

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My O5E candidate: 1982 Honda CX500TC motorcycle.


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 Post subject: Re: FrankenFerrari
PostPosted: Sun Jul 16, 2017 10:46 am 
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CONGRATS!

Next steps? More videos? Any progress since? :)

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 Post subject: Re: FrankenFerrari
PostPosted: Wed Jul 19, 2017 8:53 pm 
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russian wrote:
CONGRATS!

Next steps? More videos? Any progress since? :)

Some...but slow.
It moves
https://youtu.be/03hto9oANvk

Now it's smoking but sounding much better
https://youtu.be/2cOeKkw_0JI

A lot of little things......today I ordered a new fuel pump as fuel pressure was about 15psi when I made that last video when it should be 60.....the way I wrote ECU code it adjusts for pressure variation, but the injectors barely spray at that pressure. And the O2 sensors are giving what seems to be crap outputs. I had an error in coil dwell, noisy MAP signal...well variation cylinder to cylinder more than noise but it was messing with me I think so I added smoothing based on MAP and rpm so I get smooth without lag, cylinder MAP cages in the tuner to help sync the TBs.....just one thing after another but I'm getting there.


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 Post subject: Re: FrankenFerrari
PostPosted: Thu Jul 20, 2017 10:22 am 
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It starts and it moves - things should go easier from here!

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 Post subject: Re: FrankenFerrari
PostPosted: Thu Jul 20, 2017 3:37 pm 
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Thats good because i don't think it could get any harder!

I just added code to adjust cylinder fuel based on the cylinder MAP I put in last week. I'll leave it off and just log it's output next run and see if I trust it.

I also learned that with the ls2 trick could I have setting dwell to 0, at least in engine lan, does not turn off spark...it just screws it up. So I had to change my rev limit approach. That needs testing.

I'm making progress though......


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 Post subject: Re: FrankenFerrari
PostPosted: Thu Jul 20, 2017 8:31 pm 
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Hmmm...bashed and/or melted plug.....so much for worrying about little details. Time to get the new garage built so I have a place to pull the engine.

At least I got to hear it and sort of kind of drive it a little.....whats another year.....


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