Custom replacement solenoid system
#1
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Thread Starter
Custom replacement solenoid system
First, some background info: As many of you know, I recently completed my rebuild/upgrade (see: This Thread ). The primary function of the car is street/autocross use (with the occasional HPDE). As such, I switched to a simplified sequential 99spec setup (I've driven a few cars with a properly set up non-seq system, and I absolutely hated it. Also had no interest in single turbo). The simp-seq is nice, but still has a few annoyances. First, it still uses the stock solenoids (I had 2 fail since I finished the rebuild, and plenty before that). Second, since I removed the rack for the solenoids to attach to, the leftover hoses and valves created a complete mess under the UIM:
So I set out to learn more about solenoids and vacuum control systems so I could build an aftermarket system. Some may argue that there really is no advantage to this, but I figured that I might as well try it out and see what happens.
Basically, what I ended up building is a completely custom 5-solenoid setup (I'm running simplified sequential, so I only have the following solenoids: Purge Control, CCA, CRV, TCA (pressure), TCA (vacuum). These solenoids can be bolted together in almost any combination imaginable.
Solenoid specs:
Viton seals
Stainless steel internals
Molded coil (resistant to water, and high temperatures)
Custom aluminum manifolds
100psi rating
Use custom #10-32 brass nipples
Better flow and reaction time than stockers
Rebuildable
Cheaper than stockers (approximately $40ea)
Here are a few pics of the setup (note the stock solenoid in the picture for size reference).
So I set out to learn more about solenoids and vacuum control systems so I could build an aftermarket system. Some may argue that there really is no advantage to this, but I figured that I might as well try it out and see what happens.
Basically, what I ended up building is a completely custom 5-solenoid setup (I'm running simplified sequential, so I only have the following solenoids: Purge Control, CCA, CRV, TCA (pressure), TCA (vacuum). These solenoids can be bolted together in almost any combination imaginable.
Solenoid specs:
Viton seals
Stainless steel internals
Molded coil (resistant to water, and high temperatures)
Custom aluminum manifolds
100psi rating
Use custom #10-32 brass nipples
Better flow and reaction time than stockers
Rebuildable
Cheaper than stockers (approximately $40ea)
Here are a few pics of the setup (note the stock solenoid in the picture for size reference).
#2
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Thread Starter
Even though these solenoids can take the heat of the engine bay, I decided that I was going to move them out from underneath the UIM. Couple of reasons for that: It will help move some heat-storing mass away from that area (hopefully helping out the coils, fuel system, and intake manifold). It's a little easier to get to the vacuum lines/solenoids for diagnosis. And lastly, I think it gives it a slightly cleaner look.
I decided to place the solenoids next to the passenger fender, right behind the ABS system. There is just enough room for the solenoids in this location, and the lines aren't any longer than they were when the solenoids were under the UIM. The only modification needed, was that the wires for the airbag had to be unbolted from their bracket and lowered slightly. After that, the solenoid rack dropped right in.
Here are a few preliminary mock-ups of what it'll look like when I'm completely finished:
Testing of this system will begine shortly (later this week, after the snow has melted). I'll post any and all results.
-Rob
I decided to place the solenoids next to the passenger fender, right behind the ABS system. There is just enough room for the solenoids in this location, and the lines aren't any longer than they were when the solenoids were under the UIM. The only modification needed, was that the wires for the airbag had to be unbolted from their bracket and lowered slightly. After that, the solenoid rack dropped right in.
Here are a few preliminary mock-ups of what it'll look like when I'm completely finished:
Testing of this system will begine shortly (later this week, after the snow has melted). I'll post any and all results.
-Rob
#7
RX-7 Bad Ass
iTrader: (55)
That is simply BAD ***. VERY good work!
I've considered doing something similiar, but I was stymied trying to find a suitable replacement solenoid - looks like you found a winner!
You could almost do something approaching the '96+ solenoid "black box" that Mazda went to. It has less inputs and internally split the signals in molded plastic pathways, bigtime simplifying things. If you think about it, there's only a few inputs, but the inputs get split to different solenoids, etc.
Something like this could also be possible with the stock solenoids - moving them to that location would remove them from their heat source, and in a way moves them closer to what they're supposed to be controlling - the turbos themselves.
Keep us posted on your progress! I'm eatin' this up!
Dale
I've considered doing something similiar, but I was stymied trying to find a suitable replacement solenoid - looks like you found a winner!
You could almost do something approaching the '96+ solenoid "black box" that Mazda went to. It has less inputs and internally split the signals in molded plastic pathways, bigtime simplifying things. If you think about it, there's only a few inputs, but the inputs get split to different solenoids, etc.
Something like this could also be possible with the stock solenoids - moving them to that location would remove them from their heat source, and in a way moves them closer to what they're supposed to be controlling - the turbos themselves.
Keep us posted on your progress! I'm eatin' this up!
Dale
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#12
Call me gramps!
Coming from a 3 month journey on fixing my sequential system, I know how difficult the turbo system is to work on. I am very impressed by the progress you have made on your project -- I hope the solenoid rack works.
#13
Mr. Links
iTrader: (1)
J.S.J did something similar to his car a few months back. However, he created a boost problem in doing so and I never read that he fixed the problem (and I believe he recently sold his car).
Looking forward to hearing your results. Hopefully you'll have some better luck than J.S.J did with his project.
Looking forward to hearing your results. Hopefully you'll have some better luck than J.S.J did with his project.
#14
WOW! Looks great. You make me wish I had not done a new hose job last spring. Still, this should make things way easier to diagnose. Keep us up to date when you road test. Then a writeup on the solenoids would be great.
#15
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Thread Starter
Originally Posted by Mahjik
J.S.J did something similar to his car a few months back. However, he created a boost problem in doing so and I never read that he fixed the problem (and I believe he recently sold his car).
Looking forward to hearing your results. Hopefully you'll have some better luck than J.S.J did with his project.
Looking forward to hearing your results. Hopefully you'll have some better luck than J.S.J did with his project.
I'm still keeping my fingers crossed with my project. We'll find out what happens soon enough. I'll post my results (good or bad).
-Rob