1978 Kadett C 2l 8v Turbo Adventures...

[Jack]

Bad times. But megasquirt!

Give us a shout if you want any help, I've got a garage full of bits that you're welcome to sift through.

[rc]

wicked mate, looking forward to it

and got that screen looks cool

[The Simps]

That screen is dam fine sir!

[djivesp]

Bad times. But megasquirt!

Give us a shout if you want any help, I've got a garage full of bits that you're welcome to sift through.

thanks Jack, the tigra's keeping me going with spares etc, but ill let you know if i need anything, very generous of you

wicked mate, looking forward to it

and got that screen looks cool

That screen is dam fine sir!

cheers guys, cant wait to get to use it

got a little done yesteday and tonight:

routed the new loom all neat and tidy;
soldered all the plugs for the sensors;
found a plug from the tigra's fan sensor switch thing which fitted the kadett's rad fan plug (previously had a couple of female crimp connectors slid over the pins in the plug )
continuity tested every cable on the new loom making sure there is as little resistance as poss in the wiring;
got rid of the old wiring loom

some funky pics:
working conditions lmao

that is a bloody good light from halfords, 20 watts believe it or not lol, worth the £20 !

found some twisted wire lunacy - this was the main live to the ecu lmao


working from the megasquirt v3 wiring diagram making sure everything's connected:


doing a proper job this time round


getting there

[rc]

great work as always mate

[Brian_S]

Nice car! Love the look of it. Please don't go putting escort bubble arches on it, they look horrible IMO. The current arches look great!

[djivesp]

thanks guys, thanks brian!
the plan is to fill the top of the arch a little to make it smoother and to match the way the rear arch slopes down, but wasn't going to go as extreme as the escorts .
then make the mould

quickly knocked this up the other night to to visualise whether the tilt-over opening of the bonnet would catch anything, and to figure where to put the whatdoyawanna call it, axis i guess for the hinge

version 1 was the entire shell flopping forward, then version 2 was the bottom half of the wing behind the wheel stays in place, which is what i'll go for i think, as version 1 would catch i think, but not sure yet, i'll see how much space there is behind the wing, i remember seeing a big cavity lol!!

going to aim for 10 kilos max for the front end

[IMG][/IMG]

[vidas]

working conditions lmao

Mate that's one of the best photos I've seen lately...

[djivesp]

thanks vidas i kinda like that one too, there's something about it isnt there lol!

made some schweeet progress today and last night at 3am (couldn't sleep lol)

the relay box/pass through ecu in place, all wired up.
The resistances all check out as 0.00 ohms with the new cabling


engine loom now done, now there are less than half the wires there were, looks neat and good

organised all the connectors for the under-dash wiring:


all connected up for a test-run:


MS ecu with good earths. There's an earth lead going to the fuel rail, and one going under the ecu as you can see, then they meet in the middle in the relay box ecu. A lot of the thick cables are hidden


the old oil pressure light sender smoked up and melted when i switched the ingintion on (oops). Proper sender on the way for the gauge now


et voila!, all the temperatures are spot on, TPS works, getting RPM signal when cranking, all beautiful . The SAAB IAT sensor is awesome, putting your hand over the charge pipe for 10 seconds and the temp starts rising this is about 1023 times more sensitive than the let one!


Had a pain in the arse trying to get the lappy to talk to the MS as i have a cheapy USB>serial converter, but after a little bit of playing around with settings it was all good&sorted.

Now just the coilpack to wire up, tidy the wires up and plug in the numbers !!

[rc]

fantastic mate

all being noted down lmao

[eggman]

if the oil pressure sensor melted man is that not because it had a live thrust down it? and what type is your new one u talk about as i have a vauxhall one that goes with the digi dash (variable) if its needed

[donvaux]

nice work mate any job lot gen on earth cable lmao

[djivesp]

thanks for the offer eggman, i have one that goes with the gauge that ill fit asap Yeah there were a couple of twisted up cables, so i untwisted them and left them to get the soldering iron out, must have got them the wrong way round . I think you're right, it was fed a live and melted!

lol, that cable is awesome lmao, got a 100m reel for just over a tenner from a electronics wholesaler down the road, just the sheath is a bit thick, thats the only real difference between this and automotive cable lmao

[Jack]

Automotive cable tends to be made of lots of thin wire so that it is more flexible and less prone to breakage.

[eggman]

get yourself on to this site man the boys are real helpful http://www.workshopsupplies.co.uk/index1.html
and cost peanuts

[djivesp]

cheers again eggman, that site looks just what i've been looking for

[teaser]
* ITS ALIVE !! *
[/teaser]

lmao

[tom reid]

Loving it, even though I don't understand the wiring.

[djivesp]

thanks tom

i dont have any photos for now, as i butchered my digicam so it makes awesome cool photos but takes ages to get a good one, +i dont have a normal lens, just zoom lenses (hence all the closeups lol) .

But yeah, had the longest couple of days working on it morning till night, but now it's running, revving, driving, just a few weird problems .

Going to write up problems i encountered and how i solved them or not, it may help other peeps (RC )

#1
AFR was all over the place after trying to map the idle with a generated map. Solved it - turns out the exhaust pipe loosened itself from the turbo after megasquirt running the engine at 300 rpm on 3 cylinders and lots and lots of vibraition lmao

#2
Backfires on the first start attempt - the coilpack was wired the opposite way, igniting the charge on the exhaust stroke

#3
Engine neaaarly starting but as it starts the RPM signal is lost and it dies. After trying absolutely everything, i swapped the injectors for standard high-impedance XE creams, as mine were low impedance cossie yellows. Thought it may have been the PWM settings (current has to be limited to low-z injectors otherwise they fry!). Turns out my VR sensor wires were connected the wrong way round. VERY common reason for non-starters! After it started on xe creams, i swapped the cossie yellows back in and the suggested PWM figures are perfect.

#4
JAW display flickering with engine running thought i solved it by moving the o2 sensor's wires further from the HT leads, seemed to fix it but it started flickering again later.

#5
Rubber pipe kept collapsing that goes from inlet mani to idle valve. Turns out the engine is very strong at idle and pulls epic vacuum (specially as it was uber rich at the start), sorted.

#6
Could not get a solid low idle no matter what. Kept hunting and kangarooing and annoying the **** out of me. So turns out the Acceleration Enrichment was kicking in too early.
Basically it's there to Enrich the mix very quickly when you 'stab' the accelerator. You set how much fuel it adds and how quickly.
This Enrichment is calculated by using the TPS, and MAP sensors. You can set which one to use, or use a blend of the 2.
MAP sensors get driven up the wall by cams any rougher than mild, so i set it to use the TPS instead, as it was constantly enriching the mixture at idle because of the MAP fluctuations.

#7
kept going light headed. Fixed by having a half hour break to recover from the CO lmao. And a coffee&ciggy.

#8
Communications between lappy&ecu were flaky. Some things worked ok, like changing settings etc, but when burning a map to the ECU it would often say "cannot connect to controller" then spaz out and IAT sensor going into the negative figures no idea.
So gave up with the new laptop with the USB to serial converter, used the old lappy instead which has a serial port. Then disabled the buffer in serial port settings in device manager, and re-flashed the ECU firmware. Seemed to fix it!.

#9
RPM signal keeps dropping took it for a drive and it was next to impossible to drive it, as soon as it gets into gear it would keep conking out. NOT resets though like i used to get, seems to be linked to the crank sensor wiring .

[rc]

great bits of information there mate, this thread is gonna be so usefull when i start mine

I'm sure the problems nothing major and you'll figure it in no time

[djivesp]

cool

i'll show them problems who's boss!. I have a feeling the crank sensor wire is picking up interference. I routed it around the engine and out the back for neatness, but will try routing it away from the engine, will report on progress

[turbo gav]

Good work mate. any more info on the Saab IAT?

[djivesp]

Cheers dude

The Saab IAT is bloody brilliant, works straight out of the box . It's very quick to react, and has the same plug as all the 2 pin vauxhall loom plugs (CTS, ICV, knock sensor, injectors)

[turbo gav]

Cheers dude

The Saab IAT is bloody brilliant, works straight out of the box . It's very quick to react, and has the same plug as all the 2 pin vauxhall loom plugs (CTS, ICV, knock sensor, injectors)

part number pleaseingslmao

[djivesp]

lmao ill get it for you tomorrow if i havent glued over it

[carmad]

good project

gonna u2u / pm u soon for info on m/s lol