Cool, yeah Carlos and I go back about 25 years, back to the Big List days!
I'm excited for this joker to RUN again! Keep chipping away at it, we're all rooting for you! Dale |
It’s been a very busy few weeks since I got the harness. Many a DT/DT/DTP connectors has been crimped like a large grandmother hugging the breath outta her beloved horde of grandchildren. Truly yeoman’s work. But alas, those weeks of work will not be self-evident in the pictures below… certainly not to the uninitiated to motorsports wiring. So for those neophytes seeking accession into that realm, I first offer a precious gift: Motorsports ECU Wiring Harness Construction (rbracing-rsr.com)
Like all motivating project, this one begins with an objective… simply install the new ECU harness and accessories. Ok, easy ‘nuf. I built it some ¼ century ago so it should be easy… right? But wait, what the hell is this wire… and this wire, and this one, and why did that Navy nugget put those there when the car was first wired? And what was I thinking with all of these relays to critical components? What a foolish hack I must’ve been. But now that I think about it, hell, 25 years ago couldn’t have even found a Deutsch connector to save my life… what a wiring Neanderthal I must've been?!? https://cimg3.ibsrv.net/gimg/www.rx7...f7c6e99178.jpg <Enter stage right, the omni-present Time Succubus of Project Creep... speaking in a French voice> Sacré bleu mon amie, DO LET the good be the enemy of the perfect!! And so it begins, deliciously tempted by the franco-demon… the first shot in the unintended and unholy Wire Wars is fired! Like any good tactician and strategist, the first order is to prepare the battlefield. Every wire must be accounted for, identified and properly labeled. And that in turn requires recreating all of the wiring schematics. OK, so it’ll be a protracted but winnable engagement. <a weekend or two armed with the label maker and heatgun passes> Next, the electrical beachhead to tackle the firewall pass-throughs needs to won. A two-part, pincer movement is chosen: the main ECU harness and a separate accessories harness will each get their own breakthroughs. The ECU harness firewall mount is manufactured and installed in the OEM ECU hole. Bang. Cut. Epoxy. Rivet. Bang. It’s done. The secondary firewall pass-through makes tactical sense for the (3) EGTs, ground shielding, and the 20A Spal thermo fan… with a reserve of future expandability. An old (ECU leftover) Deutsch HDP-26-24 connector-pair gives me the connector ‘high ground’ thanks to its variety of 20-12 AWG pins and manageable size. Now where to put it? Don’t want to cut a new hole in the firewall. Needs to be on the driver side. Then I see the clear shot: an original heater pass-through can be repurpose with a little expansion. This begets the inexorable need for a new tool. JOY!! One that can cleanly cut a hole, but without requiring the center drilling of a hole saw. Here, my allies in the plumbing industry come through with the perfect ordnance … an ‘merica-made Greenlee knockout tool and die set. As luck would have it, even in the perfect size for the Deutsch connector. Huzzah! the fog of war is kind… this time! https://cimg6.ibsrv.net/gimg/www.rx7...093bf179af.jpg Greenlee Knockout tool and die set https://cimg6.ibsrv.net/gimg/www.rx7...7de044d680.jpg Greenlee Knockout and HDP Connector size confirmation https://cimg7.ibsrv.net/gimg/www.rx7...5ede348090.jpg Greenlee Knockout cutting from cabin https://cimg8.ibsrv.net/gimg/www.rx7...4670d5d3ab.jpg Greenlee Knockout cutting from engine https://cimg1.ibsrv.net/gimg/www.rx7...18adf4b792.jpg Firewall hole https://cimg2.ibsrv.net/gimg/www.rx7...217c36467b.jpg Deutsch HDP26-24 (unpinned) Installed Fuse Sub-panel The next campaign is the elimination of a brigade of critical circuit relays. While the nuclear option of a PDM is seriously considered, the time-money collateral damage is deemed still too great. However, it is the inescapable future. Just not now. So more conventional means become the plan. The front is drawn at the fuse sub-panel. It will require another bifurcated pincer tactic: a switched and constant battery voltage circuit approach. While my antiquated setup used some Maginot Line sized circuit breaker blocks from the ’90 car audio, the new setup had to me more elegant. https://cimg4.ibsrv.net/gimg/www.rx7...4099ab83ee.jpg Fuse sub-panel circa 2004 The first ‘hill’ to be taken overcoming the fact that several of the sub-panel fused circuit were >30amp, which is the ATC/ATO blade fuse size limit. While this, I would use many of the compact fuse subpanel. Thankfully, I remember that many of the sub-circuits had been removed (e.g. heaters, defrosters, wipers, stereo, et.) or given their one dedicated fused circuits (i.e. fuel pumps, ECU, and headlights). So a few hours tracing the remaining required circuits in the FSM's pages Z-23 – Z105 schematics showed that I affirmed that ALL circuits (e.g. B1, B2, BTN, et) could in fact be power within ATC/ATO fuses amperage. Some even as low as 15 amps. This vastly opened up what the sub-panel options. With this advantage, the goal became a circuit sub-panel that was mid-size (10-16 sub-circuit), AND was split into two circuit groups; I needed a +12v constant group and a +12v switch group. A call to the intel (i.e. Google) and both Bussman and Blue Sea options came to the fore. Since this would not be a long-term solution (vice a PDM), the Blue Sea 5032 was quickly airdrop into the AOR. https://cimg8.ibsrv.net/gimg/www.rx7...1c26882762.jpg The +12v constant wire was simple. However to wire the +12v switched was not going to go down without a design fight. Its biggest gun was the need for a relay that could handle at least 80 amp with some overhead. Back to ‘intel’ for support. This time, my decades long wiring ally at Ballenger Motorsports engaged with a “75A” TE relay (rate at 135A @ 85°C) that could easily win the current fight. https://cimg1.ibsrv.net/gimg/www.rx7...4ce2cb27d5.jpg All of wiring was tidied up with labels, heatshrink, sheathing, and wraps, and the valor medals and ribbons and celebrations of the victory was enjoyed. https://cimg0.ibsrv.net/gimg/www.rx7...d443b37db1.jpg Blue Sea fuse sub-panel and battery (cover off) https://cimg1.ibsrv.net/gimg/www.rx7...0d364cbc61.jpg But alas, the revelry was fleeting for there is still a Wiring War to win… |
Making some solid progress there! Doing major re-wires that like just takes for damn ever.
BTW, I hope you have been watching Bad Obsession Motorsport's Project Binky on Youtube. That's right up your alley :). Dale |
Originally Posted by DaleClark
(Post 12493430)
BTW, I hope you have been watching Bad Obsession Motorsport's Project Binky on Youtube. That's right up your alley :). Dale Cheers! |
Makes you think you just need a welder and an angle grinder and you can make a Mini :).
As the series goes along you really see them fall off the deep end of crazy detail. Dale |
Something Old, Something New
I wasn't satisfied with the original injector sub-harness. I had nicked two of the wires at the injector connectors while fixing an inevitable case of ADD dumb-assness. Coincidentally, I wasn't specific on the new engine harness termination, so I got a Deutsch DT-8 on it with the four signal wires and four matching power wires. Since my old setup was a DTM-6 (one 18 gauge branched out in the harness and four signal wires) I took the opportunity have a go at a new one. Well I'm quite pleased with myself. https://cimg1.ibsrv.net/gimg/www.rx7...e72a0c7127.jpg Injector sub-harness (2.0) https://cimg5.ibsrv.net/gimg/www.rx7...e70b8a8680.jpg Injector sub-harness (2.0) installed Lift & Main Fuel Pump solidstate relay There is a common tension between fuel pump flow capacity and fuel heating. Large pumps flow torrents, but also cook the fuel relative to bypass flow (especially at higher pressure). Small pump impart less heat, but dribble. Of course, ceteris paribus. In a particularly heinous setup, my previous triple 044 flow-throughs setup (one lift and two in parallel pressure) was a thermal and current cooker. So I took a crack at doing better with this setup. As is always the case with good design, first a little learning... from no finer hydrocarbon Aristotle than my old friend Paul Yaw. ...Well shit, his PRI lecture on Fuel Flow troubleshooting is THE best video but it's no where to be found. It shared some crazy insights including regulator and fuel harmonics troubleshooting, fuel pump dynamics, and much more. Guess I'll ask him what he did with the video next time we shoot the shit; I'll then post it here. Anyways, the salient insights were:
The pumps will be individually PWM controlled via respective ECU 2-D maps. The signal feeds a RaceGrade SSD-P at 10KHZ. Flow will be proportional to duty cycle. Presto magico...a Goldilocks-sized Fuel Flow! And it looks like this... https://cimg3.ibsrv.net/gimg/www.rx7...a3557624e3.jpg |
Unobtanium Connectors...
I'm finishing up the engine /EFI electrical work. One of the design objectives was to have firewall harness disconnects so I could simply unplug a couple Autosport/Deutsch connectors and pull the entire engine with the harnesses still installed. Easy breezy, right?!?! But like the Rube Goldburg design that I'm so prone to, an interesting part of this was incorporating the EGT thermocouples (TC) across the interconnects. You see, TC can't have any junctions made up of anything but the specific metal (i.e. Alumel or Chromel) for each wire. No normal nickel steel connector which would act as a cold junction, destroying accuracy. I found the solution in specific Deutsch DTM pins/sockets. But admittedly, I was somewhat surprised by the cost.... especially given their uber-teeny weeny-ness. Actually the more I thought about it, the more remarkable the cost seemed. I eventually concluded that they were in fact, unobtanium-priced: a 0.2517gm Alumel/Chromel pin cost about $23. If I get out the abacus... that a whopping the $2590/oz. The spot price of Platinum is ~$1000/oz and gold $1791/oz. If that ain't unobtanium, then I don't know what is. 'nuf said. :wallbash: https://cimg2.ibsrv.net/gimg/www.rx7...5f6315eb4d.jpg Will have quite a few more updates this weekend. |
Why not just get an EGT signal converter (0-5v) in the engine bay and then use regular wire into the firewall?
I have one of these under my headlight bucket. Can also use for IAT https://www.exhaustgas.com/ProductDe...D=56&BasketID= |
Originally Posted by TwinCharged RX7
(Post 12495422)
Why not just get an EGT signal converter (0-5v) in the engine bay and then use regular wire into the firewall?
I have one of these under my headlight bucket. Can also use for IAT https://www.exhaustgas.com/ProductDe...D=56&BasketID= |
Finished the engine harnesses. The LMS-EFI Autosport terminated harness is the main EFI harness. Having made (or should I say 'hacked') harnesses before, the craftsmanship, flexibility, and tidiness of Chris's concentrically wound cable is deeply appreciated. If there is any doubt, compare it to my Deutsch HDP monstrosity... it embarrasses it DR-25 sheaved neighbor.
One addition tweak was that the current arrangement allowed repositioning braided brakeline to a less obtrusive location. However, this too is temporary as it will be improved with a nicely tucked hardline in the next iteration. Like everything, a step forward causes an unintended 1/2 step backwards... now I just need to do something about the old mounting holes... https://cimg8.ibsrv.net/gimg/www.rx7...6b15e7456b.jpg Engine EFI harnesses overview Deutsch HDP26-24-29:
Deutsch HDP connector https://cimg1.ibsrv.net/gimg/www.rx7...3a8fe39b7f.jpg Deutsch HDP connector https://cimg3.ibsrv.net/gimg/www.rx7...f373acfb6d.jpg Autosport and HDP connectors |
Lovely build :-).
In your application using chromel and alumel pins looks essential. What you lose by not using them is that the temperature differential across the wiring / connector that isn't thermocouple wire / pins is not measured. In your case this would be the pass through connecter, and there is likely to be a pretty big temperature difference across this with things right by the turbo. |
got yella?
Finished the interior cornerstones. Electronics. Paint. I'm trying VERY hard to make my existing marriage to the stock harnesses work... but by God, she is untidy and capricious! I suspect we do not have a future together at this point. https://cimg3.ibsrv.net/gimg/www.rx7...bbe2de3ff6.jpg CYM painted interior (sans optional steering column support 2"x4") . . https://cimg4.ibsrv.net/gimg/www.rx7...c6df0dc978.jpg Passenger footwell electronics And then I did a compression test... |
Inspirational cleanliness on the paint and electronics, Carlos :icon_tup:
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Life's hard... but it's harder when you're stupid!!
Finally ran a compression check on the post-build, pre-startup engine. At 273 RPM (add 7% to below to normalize to 250 RPM OEM standard) in psi:
https://cimg3.ibsrv.net/gimg/www.rx7...6b6be55f65.gif Pre-start compression |
Stuck cornerseal?
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Should be fine especially if it's never run and been sitting a while. A few heat cycles will tell for sure.
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Really nice build. Keep up the good work!
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Originally Posted by Carlos Iglesias
(Post 12496627)
Life's hard... but it's harder when you're stupid!!
Finally ran a compression check on the post-build, pre-startup engine. At 273 RPM (add 7% to below to normalize to 250 RPM OEM standard) in psi:
Never let the Perfect be the enemy of the Good - some pansy ass French dude. #SendIt !!! |
Originally Posted by gracer7-rx7
(Post 12496964)
Never let the Perfect be the enemy of the Good
- some pansy ass French dude. #SendIt !!! |
Dupe Deleted
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Idle Hands are the Devil's Workshop
Waiting on my hot date with a 'well-endowed' tuner, I decided to finally give my decade old Aim MXL dash a proper mount (even if it looks a little lonely). Now that I can display everything I need on it thanks to the M1's extensive CAN broadcast, I'm planning to leave it as the lone display/gauge...at least until I upgrade to a C127 or AIM PDM32. The low positioning accounts for that intention, as well as better visibility. https://cimg4.ibsrv.net/gimg/www.rx7...cdfa457d80.jpg |
Would you mind sharing the backside of your MXL dash mounting solution?
I am working with my friends in NJ on trying to find a solve for the curvature of a blank Evo-R dash (is that what you have here?) and an MXG for a flush, clean, but most importantly solid mount I have gone international (AiM UK, AiM East Coast, draklore, FD3RS, Maxwell Manufacturing, Mako Motorsport, oldschool looks at GrandMighty) drawing at straws on a solution for something comparable here that I think shouldn't be rocket surgery, so would appreciate a view at your take I think my buddy Brian has something here, but the more solutioning I can do the better! Thanks in advance :icon_tup: |
Originally Posted by ZumSpeedRX-7
(Post 12499111)
Would you mind sharing the backside of your MXL dash mounting solution?
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The AIM dash is mount to the instrument panel with M4x10mm isolation standoffs / mounts. The mounts are held to the hood by M4 fasteners, stainless and nylon washers. The nylon washers give a slightly more pliable mount against the CF.
https://cimg0.ibsrv.net/gimg/www.rx7...b016e4139a.jpg https://cimg3.ibsrv.net/gimg/www.rx7...b5ff676abc.jpg Depending on the installed final viewing angle, I may get a slightly long isolation mount in the bottom pair of holes to angle the piece slightly more upward. Feliz Navidad!! |
You have no idea how excited I am to FINALLY see this thing run in 2022. Get it done bro!
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