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Fred's "Hotel Hyundai" 1988 Stellar! (3rd) 
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Joined: Tue Jan 15, 2008 2:31 pm
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Location: Home sweet home!
Picked up a 10l bottle of oil for 39 bucks earlier. That ought to keep it full for a while... it burns it at a rate of about 50:1.

Also picked up a piece of 3mm plate alloy to make an adapter from, good stuff. This one was free.

Figured out that the port that I didn't understand was an EGR port. Figures. It was full of carbon, I should've guessed. What I'll do is use the air port as an idle valve entry point. I'll plug the exhaust port completely.

Was nearly killed earlier when one of the tyres delaminated @ 130kph, fortunately it held together and just gave me a very surgy bumpy ride home with hazard lights on going 60kph or less. So the car is disabled until further notice and/or injection of funds to get new tyres. 4 new 175 70 13 tyres should be well under 400nzd. Unfortunately, 400nzd is about all I have left, in total, so I can't really do that, despite needing to to keep myself alive. Walking it is, then :-/ Will post some photos of the carnage up on fb later and see if I can lure in a kind soul to help me out and keep me mobile/testing.

Fred.

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Wed Feb 12, 2014 2:52 am
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It also occurred to me earlier that I'll be a lot better off with staged injection on this setup, so expect that added and pushed pretty soon. A good, proper, official, non-hacky implementation, that is. Unlike some existing, hacky, sub-par code which claims to do a similar thing.

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Wed Feb 12, 2014 9:39 am
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More progress:

Fred wrote:
1) Make an adapter plate out of some 3mm sheet alloy to interface the two differently shaped, but once-paired parts and use two gaskets

Done! All three parts made. :-)

I've also modified the injectors to fit in the clips that I have with different keying.

Still need a pair of orings before I can do flow testing, oh, and the injector driver circuitry/resistors/etc.

New item: EGR block off plate needs to be finished up and have a gasket made for it. I might just try to tap the hole for some bung and seal it that way. I also want to put PWM idle in through the EGR air port, too. This part could actually get leveraged on the car as is because the EGR may be what's messing up the idle, if it's faulty.

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Thu Feb 13, 2014 3:50 am
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Just installed the new 3mm alloy EGR block off plate and gasket on the carby manifold and warmed up the car on blocks. Gave it a rev-limit test, idled smoothly before and after. It sometimes does anyway, but this certainly hasn't done any harm. The EGR valve was pretty much completely plugged with carbon anyway.... pics to come.

Also just found an IAT with "denso" written on it. It's not a nice open element one, but if I can find a connector or solder onto it, it's usable for this non-boosted application, if positioned appropriately.

Also found two lower ex manifold studs are missing nuts, one is missing most of the stud, too. Looking for a nut to install on it now.

Fred.

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Fri Feb 14, 2014 4:10 am
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Tried to fit a nut to that stud... wound it up, not much tension at all, and it just screwed off and left half of it in the head. Tough luck, maybe at some point I'll pull it off and put two or more new studs in there. Or not.

Replaced the Chinese "tie down strap" that was holding the battery in with a piece of 3mm angle alloy, two steel threaded hooks and four nuts to suit. Looks better, more safe (metal won't go bad with heat), win.

Still plenty to do, but getting closer daily.

Fred.

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Fri Feb 14, 2014 6:18 am
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New tow bar setup all designed and ready to be cut, ground and drilled for welding! This is to replace the old one that Preston cut off and left in some garage in the 'Naki. Bad presto. Tow bars cost money, don't ya know. Good thing I built the ute one with a removable setup and still had the spare steel laying around years later. Now the ute and hotel can share tow fittings like different sized balls and racks and so forth. Jolly good.

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Fri Feb 14, 2014 8:29 am
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Anyone know what car I can find this pigtail/plug on? em_knaps says it's the common type and he may have one, if so, yay.

http://stuff.fredcooke.com/hotel.IAT.plug/IMG_8766.JPG
http://stuff.fredcooke.com/hotel.IAT.plug/IMG_8767.JPG

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Fri Feb 14, 2014 8:49 am
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em_knaps came to visit me in his MS2 powered twin turbo V8 supra tonight and gave me a plug to suit the IAT sensor, so that's all good! :-)

He hopes to find me some orings for me too, which is nice. What a nice chap he is. Except bringing a MS2 onto the property :-p

I've also written up the beginnings of an epic thread on fuel injector testing: viewtopic.php?f=41&t=2402

More news as it comes to hand.

Fred.

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FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
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Fri Feb 14, 2014 12:34 pm
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Tonight I did some more work on the injector testing: I ate the contents of the asparagus tin :-p It wasn't overly pleasant, but not entirely disgusting either. Meh. Now have a nearly perfect cylinder for measuring flow, though. I will have to take stock again and see what's left to do to get this thing EFIed.

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FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Feb 16, 2014 10:27 am
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Picked up 2 orings today, injectors now seal into rails. Also picked up a big fuel filter with fairly low restriction that I can run on the suction side before the pump. Fuel system wise, I'm only missing the rail feed fitting, which is likely unique, so I'll probably have to engineer something for that before I can do the flow tests.

Last night was the monthly meet for a local car club, I missed it. Next month, though, I intend to be there on 15" wheels with bigger better tyres and EFI via staged injection TBI. So I have... 26 full days to achieve it, a shade under 4 weeks. First step, fuel feed! Other steps:

  • Get wheels/tyres onto the car and drivable again
  • Install wideband with relay and connect to loom TA setup
  • Do WOT and cruise datalogs to get a feel for the current carby tune
  • Create usable fuel feed fitting
  • Get connectors for Jaguar and HOTEL
  • Swap in Jaguar (and the TA out for repairs)
  • Flow and dead time test the injectors[/del]
  • Figure out the throttle stopper valve thingy
  • Add staged injection code and setup config for HOTEL EFI
  • Remove carby and carby manifold
  • Install TBI manifold and throttlebody
  • Get running and rough tuned
  • Find tuning buddy and fine tune for good WOT torque/power and good cruising economy

Quite a few of these are independent and can be done in any order that makes sense for me. I'd like some help and a second vehicle around on the day of the actual swap, and for tuning afterward, too. So I guess having someone sleep over and get stuck in on the Friday night, and continue on Saturday while shops are open, with Sunday free for some tuning sessions.

Fred.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Thu Feb 20, 2014 7:26 am
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