ZEROGK
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/11 18:41:15
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Love the paint colour, look fantastic. How did you sort the handbrake with the new Wilwood setup?
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MK1corse
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/11 20:07:54
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Awesome!!! Looking absolutely brilliant!!!
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/11 20:47:40
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Good point, I need to speak to them about this, no handbrake is no option!
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/15 21:39:27
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Well it's taken a hell of an effort to date .. and this weekend the engine (finally) fired into life! - using a modified startup map I finally got the computer sync's and trigger working in the right order and it really sounds good!!!! - Some supercharger noise, and plenty of intake noise! I've uploaded a video to youtube http://www.youtube.com/watch?v=46SENlzKZ5A&feature=youtu.be Although I don't want to run the car too muc, I did want to make sure all my computer outputs and controllers were working, I have custom config for Intercooler water pump, intercooler fan, engine bay fan. They all work - The V4X is very easy to configure these outputs. I also wanted to run a log and see what boost the Rotrex makes .... WELL!!!!!!!!!! - TRY 22 PSI @ 6500 rpm !!!!!!!!!! May need to restrict this down but will leave that to the tuner. Notice I have put the catch can in the boot - plumbed back into the intake - all legal!.. Electrics done for the EMS - and now I am moving on to body. Here are some photos..
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RdS
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/18 19:08:10
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really excellent work! looking ****hot! from the few pictures of the outside so far, it looks like whoever did the paint did a damn fantastic job of it! lucky aw11. :P
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/23 12:58:58
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Nearly there ...... Off to Dyno today for a week of tuning ...
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/24 20:26:47
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DYNO RESULTS - DAY 1 - A new engine with as many mods as this one would always pose a challenge when it comes to tuning. Tuning properly anyway .. I'm not chasing HP, but drivability, reliability etc. HP is important too - but not first .. Do I sound convincing ? - Well day one the tuner concentrated on sub 4000 rpm tuning, no power runs, just smooth power delivery and a nice hot idle. Firstly, the Rotrex SC is very a different beast to turbo - we sort of expected a sharp rise in boost and then a level out, sort of like a WRX.. What we have found is the Rotrex is perfectly linear! - at 2000 rpm we are making 0.1 PSI. @ 3800 it's in the area of 8 PSI. Estimate for redline will be 16 PSI. Although no real power recording were made it was observed that at 2000 rpm dyno limited, (so foot flat to the floor but the dyno holding the car at 2000 rpm) we saw 105 RWHP. This is pretty good as it would represent something like 130 Flywheel HP (97 KW). The tuner could not get over the efficiency of the intake system including cams. What we have found is the Wolf is a bit of a 'pr--k' to tune. Tomorrow he is going to alter the sync and ref triggers to give more timing through the wolf which is limited at 20 degrees currently as it can't keep up with the signals. Also al signs are pointing to the injectors reaching their limits, so I have the company I got them from sourcing a set of 600's. Compression ratio is pretty low at a calculated 8:1 - I don't really want to, but I think it will be off with the Commetic 1.2mm mls and replace with a 0.4 mm mls. This should take the compression up to 9:1 or maybe slightly higher. Although no power figures are yet available for a final run the estimate is in the area of 300 FWHP. which was always my target(ish) - we may need to wait till the compression has been raised and the SC pulley reduced by 10mm to see this, but we will get there... BTW: IT SOUNDS ABSOLUTELY AWESOME!!!... I will post a dyno video of a power run once complete.....
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/25 20:59:10
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DYNO RESULTS - DAY 2 - I'm guttered! ... Got a call this afternoon from the tuner telling me the ECU has 'died' - just died.... no warning, just doing some timing adjustments and it died..... Leading up to the death of the ECU, the engine woudl not rev to redline. It got to abotu 6500 and then started to miss fire - not a miss fire that resembled spark, ignition, timing etc - more it like a rev limiter! .. He could not tune it out ! - even with 30 deg of timing ... The computer was struggling .. The question is - is it a programming error? - is it a software error ? - is it hardware ? - I don't know and neither does the tuner. He is going to call the support line and see where we go from here. It's already had 7 hours of dyno running, so wiring will not be the issue - if we don't get a favourable warantee result then look out !... I'm very dissapointed! ... I'm paying near $200/hour for the dyno so am already approaching $1500 - If I have to throw the ecu away and replay it then I'm up for another $2K (ECU) + another $2K for tuning - one thing is for sure is that it will not be the same brand !!!!!!!!!!!!!!!!!.. Watch this space!
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nuk1ear
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/25 23:00:40
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7 hours doesnt mean wiring is not an issue. Thats not good logic, look into it still. Which ECU are you using? i thought u said u were going to use a haltech? Honestly doesnt sound like an ecu issue, missfiring at high RPM etc
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dasic1
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/25 23:28:10
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With the Autronic in my car it had a major misfire (at 5700rpm I think it was) Turned out I had to put a resistor inside the ECU because it couldn't read the 60-2 trigger wheel once it got to that RPM.
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/26 09:38:20
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I agree it still could be wiring - although I tend to think that one of the sensors, injectors or coils have died and are bridging causing the ECU to shut down. The tuner said that if he 'half' plugs the ecu in it powers up - so it sort of points to what I am thinking.... I think I need to get the car back to diagnose myself.. As for the misfire - He tells me that it's not like a dodgy plug or coil but more like an induced rev limiter as it happens at the same rpm, pull timing and the rpm that it happens lifts a few hundred. I tend to agree with dasic1 that the ecu may be having trouble 'keeping up' with the 24/1 tooth - It may need some filtering on both cam sensors and also the LS2 coils ... I just hope it's not the ecu... BTW: The ECU I ended up using was the Wolf V4X ... I'm thinking the Link G4 Atom would bave been a better choice!!
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WIDEMR
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/26 10:58:40
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Looks awsome! I like the PWR heat exchanger and oil cooler, did PWR do the oil cooler or did you add that on? Looks really neat. I have a PWR radiator but hidden my a no name heat exchanger, mmm need a stencil and some red spray paint
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MCT_MR2
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/30 20:14:46
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For your misfire, i can't remember with the wolf ecu's, as we avoid the severely at work, but did the tuner log the ref and sync signals when the "misfire" occurs?? There can be multiple reasons for it, for starters how cold a heatrange sparkplug are you running and with what kind of gap?? It shouldn't be too much with the low comp, but check the burnback on the sparkplug, as when a sparkplug overheats, you get an ignition breakdown like described. If possible with the wolf, adjust the filter levels for the cam/crank at the higher rpm ranges. Did you use shielded wire for your sensors?? What are you using for your cam/crank triggers?? is it a standard dizzy, standard crank angle sensor or do you have a trigger wheel on your balancer. If using the standard parts, pull them out and check the airgap for the pickups, and check for play in the shaft. Also, the wolf ecu's are notorious for wandering ignition timing, it pays to check at various rpms locking out the timing and checking with a timing light. I would get the car back and diagnose the powering up process yourself. Start with just running the power and ground to the ecu, and try connecting to it with the software, if you don't have access to a laptop, you can bring a battery in and hook it up to your home computer. Check that the unit connects correctly etc.
'88 MR2 4AGTE W/ EFR6258 224.6KW @ 20PSI more to come......
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/30 20:35:43
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I'm starting to wonder if the Wolf was the best choice! ... The Link G4 has excellent features on paper and from all accounts it really good to tune. Plug wise, I am using Bosch Iridiums - These have the 4 prongs. Being powered by LS2 coils. I am concerned with the low compression, and using a 1.3mm (51 thou)MLS i have calculated it is about factory .. I really might pull the head and drop to the smallest they do 0.7mm (27thou) . This should pull compression up to near 9:1.. Sensors are from the latest model AGZE (the DLI Version) - I fully rebuilt it and have checked it on a scope -iIt's not the issue... all wiring is shielded very well too.. I just think it's the Wolf! ... mainly because the RPM where the misfire occurs is exactly the same - pull a bit of timing and the RPM misfire point rises! (too much timing pulled as power drops) ..The unit has gone back to Melbourne for testing and maybe replacement.. If they don't replace I will make sure I let everyone know the full story! - I will bin it and replace with a Link! .. My biggest issue is the ECU was $1350 and I have burned nearly $2000 of dyno time!!! - If I replace and start again I will need to spend $1500 on the Link, All the connectors (to rewire properly) and another heap of time on the Dyno! - So this excercise is looking like turning out to be bloody expensive.... better be worth it!
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Doctor
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/01/30 21:51:50
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Hi Keith, Sorry to see you having so much trouble. However it's the norm with these things that you go down a few bad alleys but you get there in the end with perserverence. Looking good though! Can't wait to see it in the flesh> Cheers Peter
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