PrevPrev Go to previous topic
NextNext Go to next topic
Last Post 09 Apr 2018 10:40 PM by  Reanimotion
Project Outline and ToDo
 17 Replies
Sort:
You are not authorized to post a reply.
Author Messages
Reanimotion
System Designer
Basic Member
Basic Member
Posts:124


--
03 Apr 2017 06:48 PM
    Going full on whack-a-doodle with the next iteration



    List of things
    AEM Infinity series 7 ECU with bespoke firmware
    The currently installed Mercedes CIS-E fuel head
    Porsche 997 GT3 82mm electronic throttle body http://www.frankencis.com/Forum/aft/34
    Porsche 996 Pedal Sensor remote mounted near engine
    Nissan SR20DET 360-4 cam angle sensor in Bosch 928 distributor body
    Porsche 997 Steering wheel
    The currently installed Porsche 996 Series II instrument cluster
    Flex Fuel - E85 fuel composition sensor on return line from CIS-E regulator http://www.frankencis.com/Forum/aft/14
    Mercedes PWM primary coolant fan controller
    Mercedes PWM secondary AC fan controller
    Replace the radiator aux fan switch with a proper NTC temp sensor for ECU control of fans

    In the waiting line
    VW/Audi adaptive cruise control sensor for AEM controlled Cruise feature http://www.frankencis.com/Forum/aft/35
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    24 May 2017 11:45 PM
    Still re-assembling the engine and front suspension so progress is slow at present
    Big dose of WYAIT going on of course

    Finally got hold of a genuine Panamera gear selector shaft for the PDK shift knob I purchased at the same time as the 997 PDK steering wheel
    so will be combining the shaft and pin with the 928 gear selector possibly this coming weekend
    It took nearly 3 years to create the hybrid VW/928 steering shaft to mount the wheel so the small delay of a few months to do the shift mechanism is definitely a bonus in comparison
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    27 May 2017 11:56 PM
    completed the hybrid shifter lever today
    Purchased a 970 shift mechanism from the UK and used the top half of the shaft from that joined to the lower half of the 928 lever
    the 928 lever was cut down to about 30mm and the 970 shaft was trimmed below the knob locking collar and turned down to 11.1mm to fit inside the 928 lower section
    Pressed the two together for an interference fit and reassembled in the vehicle
    Trimmed the inner plastic detent pin to the appropriate length and tested with the PDK knob to ensure the detent lock released properly
    Done
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    22 Jul 2017 05:29 PM
    Dusted off the AEM Infinity yesterday in order to again battle with the firmware creation using the Enginelab framework
    900 plus channels and most of the relevant features now match or exceed the AEM base with maybe half the memory space used up.
    I've left out the obviously useless things such as VVT/VVC and dumb backyard features like giggle gas (N2O)

    The bespoke setup is basically lambda based closed loop for K-Jet, with SD/VE idling along in parallel for VE table building and log comparisons
    should be able to back-calculate fuel head position based fuel flow and actual engine VE as the K-Jet is pretty much just calculating fuel demand for 1:1 lambda then doing a PID differential against required fuel and target AFR.

    That's it for now, back to assembling the beastie
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    24 Jul 2017 04:54 PM
    Bigger, Better, Faster, Stronger !!

    going Coil-Near-Plug with GM LS1 coils and the AEM Infinity. Will retain the SR20 crank/cam position sensor in the Bosch distributor and add a billet cap to seal it off.

    Deliberated for some time over this as the distributor based CDI was kind of worth retaining for many reasons, none of which involved any simple way of getting the stock 360+4 Nissan trigger wheel to co-exist with a rotor button and distributor cap in the stock Bosch Dizzy. Plus it simply hobbled all of the cool timing and knock capabilities of the ECU, so bye-bye nostalgia, and hello 21st century ignition!
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    27 Jul 2017 12:07 AM
    Central Electrics Panel (CE) is being backdated to 1979 configuration, mainly to allow incorporation of Hella Solid State relays for HVAC fan and lighting controls as well as the foundation relays and connections for the AEM Infinity, plus will be reinstating the discrete relay configuration for the headlights. Outcome should be a hybrid CE/PDU without all the hullabaloo, especially as the Infinity has the 10 free injector outputs we can use in addition to the dozen or so normal GPIO channels, meaning ECU control of relays and such can be supported by the required logic in the Franken8 model.
    Harder, Better, Faster, Stronger --- indeed!
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    28 Jul 2017 07:41 PM
    Porsche 996 Pedal Sensor remote mounted near engine


    scratch that - now implementing Ferrari F430 Alloy pedal and sensor in place of plastic pedal and remote mount sensor

    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    14 Aug 2017 10:25 AM

    Posted By Reanimotion on 27 Jul 2017 12:07 AM
    plus will be reinstating the discrete relay configuration for the headlights.


    No advantage to this change, so retaining the integrated relay

    Have added relays for
    Aux Driving Lights
    Kick Down
    AC Compressor
    Infinity ECU
    General EFI power (coils etc.)

    Documented wiring changes and all changes made in such a way as to retain original in vehicle functionality should the stock CE panel be reinstalled
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    14 Aug 2017 10:30 AM
    for installation of the electronic throttle body, the primary issue which needed to be resolved was the mechanical Bowden cable for the transmission.
    Solution is to have the Bowden cable directly connected to the throttle pedal and either remake the cable to suit or run a bell crank transfer pivot on the firewall under the coolant reserve tank on the passenger side
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    14 Aug 2017 10:32 AM
    completed custom shaft for distributor body to mount sensor disc for Nissan RB26DETT CAS
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    20 Aug 2017 05:50 PM
    Greasy fingernails again this weekend

    Completed install of the front cross-member and lower control arm mounts
    Installed cam belt and tensioner
    removed CDI box and coil
    found I need to replace the RHS upper ball join boot as it's developed a split

    Printed a 3d prototype to verify fitment of the DBW throttle housing adapter, clocking 12.5 degrees works perfectly
    Intending to have it CNC'd in Acetal or Aluminium, but will try a local 3d fab house for laser sintering if it's economical as our CNC guys are notoriously overbooked.

    Bowden cable for tranny will need to be custom made locally, and will now go directly from pedal to trans using original throttle path and existing trans path crossed over engine

    Decided to delete the cold start valve and TTS switch, and instead machined up a custom m8x1 version of our 100psi pressure sensor to fit into the top port of the fuel distributor for overall fuel pressure monitoring. This will give the Infinity both system and lower chamber pressure values for logging and calculation. Combined with fuel ethanol % and fuel temp using the Flex fuel sensor and we should have enough info to back calculate injector flow.

    DBW APP 1&2 as well as TPS A&B confirmed in firmware and on Infinity pinout

    Still need to look at routing evap-purge valve and PCV from oil filler top. Contemplating reverting PCV back to the air filter as a way of minimising oil residue in the intake. External catch can for condensation and maybe a new billet cap to avoid the massive custom hose, should do the trick
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    04 Sep 2017 12:42 PM
    a little more progress this week.
    Mechanical,
    front of engine buttoned up and radiator reinstalled for the first time since it's removal 18 months ago
    Water bridge mounted using DLC coated Ti bolts, which means there should never ever be corrosion , unlike the factory zinc/steel setup.

    Electrical,
    Small issue with the rewiring of the CE panel, it appears the plan to replace most of the relays with Hella 4RA solid state units is not going to work with the AEM infinity. Most of the low side outputs have flyback diodes and therefore are not happy with anything that is 12v constant powered, and as the 4ras are ground switched but take the sense feed from the primary 30 input rather than the traditional 85/86 pair, I can only utilise 4 of them on the limited no-flyback outputs - bummer.
    Have 993 coil-plug wire set coming from Pelican and will used a few of these as a basis for the required custom GM->Porsche coil to plug leads. Simpler than cannibalising the distributor leads that came off the car, and cheaper than purchasing a genuine Beru crimper. Plus it turns out the leads purchased from 928 International back in 2010 were not crimped correctly and pretty sub-standard overall.
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    23 Sep 2017 05:46 PM
    it also makes sense to eliminate the Speed Density / VE setup from the MicroSquirt and go MAF

    Funny thing is - it then by necessity goes to pure Lambda target based tuning as VE is irrelevant when we know airflow, making the tuning simpler
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    27 Jan 2018 12:28 PM
    Tiny progress over Xmas break unfortunately, still, I now have custom power steer and oil cooler lines completed and the engine harness main power cables are reconfigured to allocate current to both the body and the engine bay electrics separately
    Single HD cable between starter and alternator
    then alternator to Jump Post for original body feeds
    and additional alternator to fused distribution point below jump post for fan controllers etc.

    Dash shot found
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    25 Mar 2018 12:29 PM
    Ignition coils and fuel supply and return lines are in the same area on the right hand bank so relocating the fuel lines seems to be the smartest choice
    the deep metric m16x1.5 connections at the body and the barbed fittings for Cohline nylon fuel lines is problematic
    the idea of migrating to modern quick connect fittings is really attractive, extending the hard lines to either the strut tower or higher on the firewall by using stainless steel hard lines - then 3/8 push connect BMW fittings is where we need to be from a longevity standpoint.
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    07 Apr 2018 06:51 PM
    some progress made this week.

    CE panel changes required to window relay and central lock power and removal of the DEI 530T window controller
    Now using a 928 GTS window module which includes comfort close and delayed power to operate windows after ignition off and when door is open
    928 618 040 00 or 1L0 959 875

    997 MFSW module obtained and awaiting VW/Audi LIN to CANbus mfsw controller 451 relay (1J0 907 487 A) to see if we can integrate full button behaviour over four wires in clock spring

    Picked up a couple of 3AN to 1/8NPT clip mount adapters to relocate the fuel pressure sensors away from the gaps between the inlet runners. should now have balanced space on both banks for symmetrical mounting of the LS1 coil packs for CNP ignition
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    07 Apr 2018 06:56 PM
    positioned the throttle pedal and trimmed the firewall sound insulation for mounting

    BMW mini alloy coolant reservoir placement and plumbing finalised, .75mm gal steel bracket being cut and folded to mount the unit to original points

    6AN power steer return line completed and capped, oil cooler lines completed and installed, engine harness partially completed and battery power from starter to jump post and distribution block routed
    Reanimotion
    System Designer
    Basic Member
    Basic Member
    Posts:124


    --
    09 Apr 2018 10:40 PM
    You are not authorized to post a reply.