The neverending march of progress

[Alex L]

So the 84 made it through the reunion without serious issue, and we all know what that means! time for more power!

as the dyno sorely pointed out, the ranger roller cam has got to go. thinking boport 1.9.

the OMGHUGE K&N is just silly, and im almost pegging the 60mm MAF in blow through configuration. intake / air filter is going to get relocated to the passenger fender, and the MAF moved to draw through. likely do the op-amp conversion while im cleaning things out.

install some sorta timing mark. eyeballing only gets you so far.

move the WBO2 down to the lower part of the downpipe, replace stock EGO sensor up top.

remove/disassemble/inspect gearbox and diff. been making a lot of noise lately.

im sure ill think of more stuff as time goes by

[Alex L]

boport 1.9 cam ordered. should free up some power over the ranger roller.

i think the intercooler piping is going to get strain reliever bolts welded to them. had enough trouble with the connectors blowing apart at 18psi.

[Alex L]

boport 1.9 in stock; moates quarterhorse just ordered. pics as soon as i start getting dirty. :D

[Alex L]

boport cam installed. nice putter to it at idle. heat cycled it a few times to get the HLAs pumped up. finally starting to quiet down.

having a bit of trouble with the QH1 and the la3_maf.bin from the binary editor site. no matter, think i got BE2010 to work with caroth's bin.

[Alex L]

as soon as i data log the 1.9, getting close to 80% duty cycle on the 35# injectors.. at 4krpm @ 10psi of boost. so out they come, in go 83#/hr. out comes the blow through 65mm MAF, in goes the 90mm MAF.

start to do more data logging, and the power steering pump starts failing, fast. turning the pump by hand feels.. crunchy. started pulling all the crap off the driver's side of the engine, manual rack ordered.

[Alex L]

it lives! got the first 2 volt mapped out on the xfer, no more 'transfer creep' from the turbine backflow. alternator bracket fabbed up (ya'll are gonna get a kick out of it at the reunion, its ghetto redneck), and it fires right up. timing belt idler is shot, now that the PS pump is gone, i can plainly hear it whine. think ive got spare though..

now to remove the TRW rack and put in the manual rack.

after that, durability testing, mapping the MAF out to 90% duty on the injectors, then in go the big hoss injectors.

[SVORob]

it lives! got the first 2 volt mapped out on the xfer, no more 'transfer creep' from the turbine backflow.

Are you sure you are from Kentucky?
We aint got that kinda vocabulary down here
but congradulations I recon

[chalkys_explorer]

maybe he went to private school????

[Alex L]

maybe he went to private school????

naw man, iz proad 2 bee a graduated from the boone county plubic skool system!

[Alex L]

just got back from getting an alignment done. boy, the manual rack is going to take some getting used to. it has a lot more road communication then the busted power rack; not nearly as much effort as with a powerless power rack, but its definitely not a one handed drive anymore. nice to be able to drive the back roads and not do the hand shuffle on the hairpins though. think i maybe got a half turn in either direction.

[Alex L]

so from the way home's datalog:


WBEGO LOAD MAFLB MAFV PW1 RPM TP INJDUTY
11.45 2.0 23.64 3.6 20.96 5949 2.16 103.9293
11.46 2.0 24 3.6 20.68 5949 2.15 102.4999
11.5 2.0 23.64 3.6 20.59 5910 2.11 101.4145
11.22 2.0 23.55 3.6 20.36 5879 2.15 99.75646
11.41 2.0 23.28 3.6 20.04 5963 2.13 99.58466
11.48 1.9 22.55 3.5 20.33 5831 2.07 98.77711
11.45 1.8 20.35 3.4 20.07 5705 1.92 95.38855
11.44 2.0 23.28 3.6 19.85 5754 2.15 95.19134
11.26 1.9 22.19 3.5 19.46 5865 2.06 95.08791


:eek: and it didnt go *boom*. guess im putting the new injectors in first thing tomorrow! didnt think i was getting on it _that_ bad...

[chalkys_explorer]

Looks like you got lucky!!!!!!

[Alex L]

Looks like you got lucky!!!!!!

yeah, less then 1/2 throttle @ 6k and 10psi of boost and hitting the injector ceiling. i <3 this 1.9 cam :)

[Alex L]

the 83#ers went in without too much drama. remember kids, just started enrichment is a multiplier table, not an adder...

last datalog looks a lot better:

WBEGO LOAD MAFV PW1 RPM TP TS INJDUTY
12.61 2.315 3.5 8.46 5005 2.12 0 35.26656
12.69 2.218 3.5 8.74 5126 2.12 0 37.31104
12.67 2.229 3.5 8.61 5045 2.12 0 36.19201


starting to hit the areas of the fuel table where stock is richer then the 12.5 target i was using for tuning. so next step is to get a narrow band O2, feed that into HEGO in, and get it to settle out under idle/cruise. then i get to work my way up WOT tuning to red line, and then off to the concrete dyno!

ill get some pics up when i get back this week.

[Laredo]

How low does your pulse-width on those monsters have to be to get it to idle?

[Alex L]

How low does your pulse-width on those monsters have to be to get it to idle?

i dont have my logs in front of me (shut the tablet off before i left this morning); i wanna say its around 1.5ms @ 1krpm. the dead time on these are huge, my base offset is something like .8ms. if i have base idle under 900rpm, it starts to hunt.

[Alex L]

wonderful day out today, and took 'er up to the store for beer a few minutes ago. starting to reach into 3/4 throttle without things going *BOOM*. this cam is wonderful, just pulls and pulls and pulls. the manual rack makes the front wheels feel like an extension of your hands.

metering with the 90mm maf is rock solid, now that i put the airflow straighteners in. need to plumb in the BPV soon. need to get the backflow fix merged into my .bin, sometimes it stalls out when comming to a stop sign after a good pull.

still got some rattles around the gearbox to find. and it sounds like the input shaft bearing on the gearbox is starting to howl.. louder. time to go tranny hunting again..

PW @ idle is 1.2~1.5ms. the kicker is, so far it still fires on the first crank, hot or cold. <3 technology.

when i get a chance, its time to take the last pair of dinged up SVO wheels to the wheel repair shop, then its time for some serious track rubber... :D

[Raven855]

I have been asleep, what is your setup. Any pics yet?

[Alex L]

from intake to exhaust:
90mm lightning MAF
holset HY-35
stinger FMIC
stock TB
stock 84 intake
83pph injectors
backyard ported head
boport 1.9 cam
e6
3" downpipe, 2 chamber flowmaster

ill pull some pics later today, been to busy wrenching to stop and take pictures ;)

[Alex L]

some pictures.

[Raven855]

Nice pictures and interesting project.

[Alex L]

thanks raven!

took the 84 for a drive for mother's day. got some serious back flow issues when coming to a stop after thrashing it. which sucks, cause caroth's bins dont have the airmass clip fix and i dont have a clue how to patch hex in be2010.

so tonight i get to play with the stock LA3_MAF.bin. last time i tried it, the fuel pump wouldn't shut down. hopefully the MAF airflow clip function doesnt overlay the extended MAF transfer function. i really really want my 50 point MAF transfers back :(

[Alex L]

backflow issue resolved. think i also have enough room to run out the MAF to 50 pts once the next build of binary editor is released.

of course, the new bin is slightly different then the one i was using from caroth. still have some tweaking to do in the IAC functions, and the fuel scalars, but its getting pretty close.

but now, its supposed to rain for the next few days. might give me a chance to flush the fluids in the drive train and see if i can get it to quiet down a bit...

[Alex L]

added half a quart to the rear end, quieted things down a bit. after crunching the data logs, the adjusted maf curve is REAL close to the stock 90mm transfer curve :doh: so i dropped the stock curve in, flipped on 'force open loop at idle', and viola! purrs like a kitten. trimmed down the injector offset to get idle -> pt transfer steady.

WOT pulls with the stock MAF transfer hit 11.5 right out of the gate @ 12psi.. but i still have an oil control issue from what im presuming to the valve cover and rear main... hits the cat when it drips and causes all sorts of smoke. gonna get a http://www.summitracing.com/parts/SUM-120108/ and run dedicated lines from the crank and valve cover to get some positive evac. if that dont fix it, guess its getting pulled and new seals going in. if that dont fix it... well, ill cross that bridge when i get to it.

bumped the idle up to 1100, 1000 would sometimes die while comming to a stop and i couldn't get it trimmed out using backflow clip. had to muck with it to keep it from flooding on decel, but this seems to work well with my combo
16384 7.0
4000 4.0
2500 2.5
2000 1.8
1500 1.2
1000 1.0
0 0.8
im sure that will get changed once i get the BPV plumbed back in. also tweaking on 'IAC - Desired Idle Airflow in Neurtal' and 'IAC - Desired Idle Airflow in Drive' to be
16383.0 3.94
2500.00 3.94
2000.00 4.40
1500.00 3.00
1200.00 1.60
700.00 1.30
0.00 0.00 now the 1.9 softly glides to idle, rather then falling to idle, missing by 500 rpm, stumbling for a few moments, and then hunting between 1500 and 800 for a few seconds... still bucks a bit at 1500 when idling down, so still need to futz with IAC - Desired in Drive a bit

[Erics SVO]

Nice! Sounds like your getting there!

[Raven855]

Good info Alex. You are getting this tuning thing down pretty well it sounds like.

[Alex L]

Eric, Raven, thanks! its a bit of a learning curve, but i think im making a bit of progress. there is so much information out there in different places that its hard to track down things.

tuning changes today:
AFR hunts a bit at idle, expected with a lumpy cam, but increased # MAF samples to avg at idle from 3 to 7, and it seems to have smoothed a bit.

now my issue is that i appear to be hitting a airmass clip at 32lb/min. load was only 2.5, so its not a load clip. all my airmass clip bypass flags are set. *shrugs* time to start digging through the archives.. already hitting 3.8v on the maf, and i still haven't put the boost controller back in.

[MikeFleming]

now my issue is that i appear to be hitting a airmass clip at 32lb/min. Yes, that's the default. You have missed a doubler setting somewhere. You using Roth's base MAF binary? They all have the doubler values set to 64 Lb/min.

PE or LAx?

[Alex L]

la3. was using roth's bin, but then switched to johnk's (i think, it was from the binary editor site) for the backflow fix.

i couldn't find where things were being doubled in this bin, the injector size is set to have 112max, so im presuming its in the logic somewhere...

had some initiative and installed the exhaust evac system; now my dipstick is blowing out.. AGAIN. time to break out the leak down kit and see where the bores are, and if its even worth dicking around with...

[Alex L]

fixed the crankcase pressure issue. just required a slight modification to the PCV system (aka: gutting it)

also, seems like that fall-on-its-face-at-32lb-airflow was a non issue. closed loop at cruse was trimming the fuel richer, causing WOT to go hard fat < 10:1. my 2.7-3.0 load bins are targeting 11:1 already, so its a short jaunt from 'slightly richer then RBT' to 'wadda trying to do, hydrolock the engine?'. just happened that it freaked out right at 32lb/min. datalogs up to 35LB airflow show rock soild 11:1 now.

[MikeFleming]

Is that white thing at the front with all the hoses where the 'shine comes out??

[Alex L]

Is that white thing at the front with all the hoses where the 'shine comes out??

no, that's what the coke bottle behind it is for!

[Alex L]

AFR LOAD MAFT RPM INJDUTY
11.2 3.022 38.2 6321 64.64251
11.12 2.858 37.8 6614 68.43098
11.12 2.858 37.8 6614 68.43098
11.12 2.858 37.8 6614 68.43098
11.18 2.849 37.54 6588 66.99545
11.11 3.079 37.01 6010 63.1558
11.11 3.079 37.01 6010 63.1558
11.11 3.079 37.01 6010 63.1558
11.1 2.931 37.01 6313 67.01463


giggty giggty.

[roberto2000]

alright!!

[Alex L]

well, the t5 didnt last long under that abuse... 4th is making a death rattle, and 2nd is starting to grind. getting noticeably worse after every lunchtime drive around the block. since this thing has become absolutely scary to drive, and im really hard on drivetrains, out comes the T5, and in is going a reverse full manual C4.

im already classed out into EP, so no harm there. 2.7x torque multiplier @ 3800rpm stall should pull pretty nice outta the hole.

[Alex L]

feh. feh feh feh feh. went out to clean up the grounds (20,60,49) and now the fuel pump wont run. no click from the fuel pump relay either. *grumble*

[MikeFleming]

... 4th is making a death rattle, ... Huh? 4th is straight through - just clamps the input shaft to the output shaft - NO torque is applied to any gears. Only the mainshaft bearings are spinning. You got oil in there, yes?

went out to clean up the grounds (20,60,49) and now the fuel pump wont run. no click from the fuel pump relay either. *grumble* So you fixed it one too many times?

[Alex L]

Huh? 4th is straight through - just clamps the input shaft to the output shaft - NO torque is applied to any gears. Only the mainshaft bearings are spinning. You got oil in there, yes?


yup. im guessing its some sort of harmonic vibration in the drivetrain. it only happens in 4th. 3rd and 5th are quiet, 4th gear, wummamamamamama.

So you fixed it one too many times?

no, it didn't work when i went out to start the job. :( didnt have a new relay to put in it, so i went ahead and ran the new grounds. got the relay this morning, and still no love. no juice at the tank (big pink wire with dashes is +12v to pump, right?)

*goes digging for the circuit diagrams to work backwards*

[SVOeric]

yup. im guessing its some sort of harmonic vibration in the drivetrain. it only happens in 4th. 3rd and 5th are quiet, 4th gear, wummamamamamama.




hummm 4th is the one gear that isn't technically a 'gear' it's straight through, basically locks the input shaft to the tail-shaft.
makes me think if you have some input shaft play, or the tail shaft bushing is shot in your T5.
I can see how more vibs might pass through from the drive-shaft in 4th tho....

[Alex L]

makes me think if you have some input shaft play, or the tail shaft bushing is shot in your T5

the whole drive train is pretty beat up. it'll survive the reunion. i think.

got the new harness kit for it, and wooo wee is it purdy. moving all that crap wedged into the kick panel to the rear hump near the battery. ill be sure to take lots of pictures along the way.

picked up an air/water intercooler kit. IC, radiator, terminator cobra pump; gonna put an ice box in for a second stage intercooler. not sure how it will all fit though...

[Alex L]

pulled the old harness and routed all the wires in the engine bay. found a few more wires up in the dash/kick panel area that are turning to power. :( tomorrow ill get the breakout box mounted, and get the wires routed through the cabin. kit comes with enough wire on each sensor to mount the ecu anywhere in the car. dedicated grounds to every sensor.

for some reason, the ac clutch wot cutout pins are routed into a connector right off the eec plug, and not through the break out box. :boggle:

hopefully it'll be back on the road tomorrow evening. :D

think the second intercooler will fit in the driver fender, but it'll take some finagling to plumb up.

[Erics SVO]

Wow, that is a nice setup!

[Alex L]

worked all evening on wiring things up. measure, fit, route, cut, strip, crimp, screw. repeat ~50 times. but this morning, after hooking up a fuel pump circuit i didn't think id need last night, it fired right up. all sensors seem to be reading correctly. no fuses blown, no smoke pouring outta the breakout box.

just need to tie everything up, get the new TPS to fit (stupid smaller bolt holes.. grr), and should be back on the road.

[MikeFleming]

no fuses blown, no smoke pouring outta the breakout box. I know from personal experience that you can add both of those at a later time.