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Megajolt2 RevA board snapshot (teaser?)
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Hi Brent,

Not to poke you *too* much, but do you have any "approximate" ideas on when you might have some beta-test units of the Megajolt 2 out in the wild for us to play with ?

My friend Sam at Come Racing is getting pretty keen to find a new programmable ignition system to sell with his new 396ci alloy-head engines carburetted-option engines running LS1 Coil-on-Plug packs - This guy is a *serious* performance engine shop - they are probably Australia's biggest aftermarket V8 shop, and have been building top-notch race and street engines downunder for *30*-years. They even cast their own alloy heads, blocks and stroker crank kits and wholesale them around Australia. If he likes it, you will likely get some great sales volume and publicity from him.

He has a Superflow 901 Engine Dyno (have a look at his Blog - http://www.comeracing.com/ for info on his latest 600Hp normally aspirated street engines ($16k worth!) and knows fuel injection systems inside out - he was the first in Australia to reverse-engineer and make possible recalibration of the factory GM/Holden EFI Unit, and combined with myself (an Electronic Engineer whos done about 6x MJ installs and the nixie-tach, I reckon we'd make a pretty killer Beta-Test team for you. not to toot my own horn too much I hope Wink

We can even do some back-to-back testing on the Dyno of the Megajolt vs an Distributor and supply you with the test results and some video's of it running on the dyno.

Hes actually in the USA for the next 2 weeks and was interested in visiting you and saying hello, but then we discovered you're in Washington (If I read your address right), while he's in California, so probably a bit far to visit. so he's pretty keen to get his hands on one.

He keeps asking me if there's any news on the MJ2 after seeing all the MJ's Ive been doing. He started setting up a Megajolt 1 on an engine, but then decided he didnt want to run 2nd hand EDIS modules on his engines.

So, Any ideas of roughly when so I can tell him ?

regards

Brett

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Hi Brett,

Thank you for the poke- I do appreciate it! We're grateful for the interest and excitement expressed, especially from an engine builder of the caliber that Sam @ comeracing.com represents. Drop me an email at brent (at) autosportlabs.com and we can discuss further. It is a project high on the priority list- especially now that we have our new lab space mostly sorted out.

However, something significant stands out. Sam or anyone else should not *not* be worried to run a Ford EDIS module. These things are incredibly well engineered; it will take much testing to approach the bullet-proof reliability that these modules offer. Frankly, I'm glad they exist so they are the 'gold standard' to compare against. So for Sam, a Megajolt + EDIS solution should be something he should start testing with immediately, and without hesitation.

Secondly, for beta testing I would hope a rickety, old, throw-away engine would be the test mule for initial testing Smile

Thirdly, Can I hand deliver to AUS? I've been dying to visit that part of the world! Very Happy


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Thanks for the reply Brent,

Its not just that the EDIS module is 2nd hand, that was just his primary concern.

2nd is that they are harder to source here in Australia.. none of our Factory cars were fitted with them - most of ours used the EEC-IV controllers. There seem to be plenty available on ebay, but that could change.

3rd is that the EDIS is a Ford (Motorcraft) part. Sam's not a totally one-eyed builder (although I have heard him mutter "Ford Shit" on a few occasions Wink ), but some of his customers are and might balk at Ford Parts on their Holden Motors (some of the Aussie Holden builders are pretty "dyed in the wool" as we say here.

4th is he wants to use the LS-1 COP packs for his engines, since he has proven them on engines making 800+HP and they mount nicely on the rocker covers and are available new. The standard EDIS packs (and leads to suit) arent available here. I mount/adapt the Holden V6 coil packs for the conversions I've done so far (Im making a mount plate for my 265 Hemi at the moment), but hes not confident of those packs ability to provide enough spark energy at high RPMs and power levels.

and he would prefer to use the simple bolt-on LS1 packs for looks, ease of mounting without having to make mount plates and proven peformance., however, they have an electronic ignitor built into the packs, and hence cant be driven by an EDIS/MJ1 combo.

5.th finally, he's concerned about the high RPM capabilities of the EDIS. He regularly builds engines that spin 7500 - 8500 Rpm and there seems to be some question as to whether some EDIS modules will handle that or not.

When he ran a MJ1 on a test engine, they had some popping and kicking problems at about 4000-5000 rpm, so took it off again to continue their other testing (I wasnt there at the time)..

I came down later and saw the problem first hand. it was a like mid-rpm-stutter or mis/back fire. The engine seemed to intermittently "shudder" as if the wrong cylinder was being fired at the wrong time, or the timing was suddenly way out for a split-second.. then it would clear again. It seemed to happen worse under heavier load.throttle settings. I checked the solidity of the VR sensor mount and 'scoped the signal coming from it, (a bit wobbly, so they strengethened it, the signal stabilised but it still did the misfire), checked the power supply and so on. All OK.

I suspect the problem might have been with either 1. the factory EDIS packs/leads they were testing with, We wondered if the factory ford coil packs couldnt put out enough voltage to light up a 500hp engine at high rpm, or the maybe 2nd hand EDIS leads were sus..
or
2. *maybe* that they had the EDIS module mounted a bit close to the coil packs for my liking - it was only a few cm away and the spark leads ran fairly close to it as well.. Maybe some EMI had bothered the EDIS electronics, although they are pretty tough by all reports
3. a faulty EDIS module.

I supplied them with a 2nd EDIS8 module, and we were going to rewire it to use new holden coil packs, but they didnt get around to testing further before pulling the test-mule motor off the dyno to run a customers engine.. Soo all in all, not a great MJ1 expereince, although all the street car conversions I have done are running fine..

And as I said, Sam was more interested in using the LS1 COPs anyway, so he decided to wait for the MJ2, but hes getting impatient now Smile If you really think the MJ2 is a way off, I can have another go at convincing him to try the MJ1 combo again with a new module and packs, but what about the high rpm limit ?



Finally, another builder who is using them is a bit concerned that the MJ2 is still using waste-spark. He likes building performance LPG fuelled engines and apparently waste-spark LPG fuelled engines are known to back-fire on start with the open-valved waste-cylinder firing. Is there any possibility the final MJ2 can have an additional 2 outputs (for 8 total) -they dont need to be drivers, since the LS1 COP packs have their own inbuilt ignitors) and will run in non-waste spark mode ? The reason I bring this up now, is Sam and I were wondering if the waste-spark might have been the reason for the shudder/misfire when testing the MJ1 on the 'mule engine, even although it was running Petrol.

So, If the MJ2 is still a way off (?), can you tell me how I can convince him to give the MJ1 another go by addressing any of these concerns ?

As far as visiting Aus goes, we're in the middle of winter here right now and its struggling to reach 15'c (60f) during the day, with nightimes down to 0 degrees C (32f), so its cold and wet, not the greatest time to visit Oz, but if you want to arrange a trip down here, we'll be hospitipable for you Smile You might want to wait another 6 months until its summertime though..

You never know, if you arrive with a MJ2 in hand, Sam might even stump up an airfare for you (dont count on it though, that was just my idea Smile )

regards

Brett

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Hi Brett,

Excellent points- and no issues with them Smile Even with the brand bias / loyalty; even though it doesn't make sense, it can often be seen as 'tilting at windmills' (if you understand the reference) to try to push the issue. And I'm well aware of the EDIS-8 scarcity in your part of the world.

What Sam needs is actually the Megajolt2 variant without in-built coil drivers- "Megajolt/COP" . Think of the Megajolt2 we've been showing here, but with the high powered coil drivers cleaved off and logic-level outputs to coil packs with built-in drivers/ignitors, such as the LS1 coil packs or the coil packs from a 2001-ish Toyota Corolla GTS. The good thing is that it will share common firmware lineage with Megajolt2.

More info here http://www.autosportlabs.net/Megajolt2

Sam might have been experiencing the upper rev limit of the EDIS module- if his engines spin in the high 7's to 8's there will likely be an issue with reliable high RPM operation. We're targeting the Megajolt2 family to suport 10K+ RPMs.


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Hmmm. With the M2-COP, I have a question. Since the outputs are logic-level, they should be able to handle multiple COP units then? A twin-plug six using 6 outputs that operate 12 COPs should work, no? That would be sweet and simple, but if I need two M2s, that would be ok too, I would just have to split the VR output to the two units.

I really want to do this especially with the old-school mechanical injection. I really like my Megajolt v3 with carbs, it continues to be the best change I ever did, thanks Brent! Very Happy

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Eventually, I'd like to try non-waste COP on my 6 cyl corvair engine.
To start, though, I was thinking eDIS, since coils that can take the air-cooled heat may be tough to find.

Which version of Mj2 should I procure?

Next time I'm at the yard, I'll hope to find a sweet 6... cylinder mustang and rob some modules. Gotta remember to get a cross-reference of what year and make vehicles to swipe from. Since my coworker has a CNC mill in his garage, I think I can cut the trigger wheel teeth on a spare harmonic damper and "go to town"

If I have to wait for COP and skip eDIS, that's fine, too, but I'd still like to have 6 drivers - I have available a set of COPs from a dodge truck hemi engine, as well as a Jeep Cherokee. I wonder if they have drivers and such. anyone? I also wonder if they're 'deep' enough to add the perimiter seal to the engine sheet metal.

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Thought I'd share a shot of the Megajolt2 Rev "A" board on the bench, fully assembled and ready for some testing.

Already, we're planning on collapsing the CPU Module down onto the main board- kind of a shame as that CPU module board turned out to be a neat little device. Might make a run of those separately. Anyway, enjoy Smile

Edit: bummer, image is blurrier than I expected...




megajolt2_on_bench.jpg
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megajolt2_on_bench.jpg



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I'm sooooo buying an MJLJ2 when they're ready Very Happy.

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Oh yeah!!!!

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Very nice Brent!!

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I love that everything is sooooo neat and tidy Very Happy Very smart!

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If you don't end up attaching the CPU module directly to the main board, I'd recommend a set of holes or loops for some form of captive hardware (a nylon bolt/nut, perhaps?), or perhaps a dollop of hot glue or clear silicone beneath or on opposite corners. Doesn't look like much mass, but ya never know what happens at certain RsPM vibration-wise. In my ham radios, it's common for accesory boards to come with double-sided tape to keep 'em in place due to jarring etc..

That being said, the board looks quite fluid; hope that beefy ground plane does it's job!

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Thank you. Excellent point about vibration- that CPU module is definitely going onboard for a variety of reasons and we're moving to a QFN package for the same ARM processor. In fact, here's a sneak peek on what you will see in our "compact device" form factor, to fit our new enclosure. e.g. Megajolt/COP and other things. Smile

http://twitpic.com/2eqaz2

(if you're not following us on twitter you're missing a lot of updates. Just saying Smile )


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brentp wrote:
Thank you. Excellent point about vibration- that CPU module is definitely going onboard for a variety of reasons and we're moving to a QFN package for the same ARM processor. In fact, here's a sneak peek on what you will see in our "compact device" form factor, to fit our new enclosure. e.g. Megajolt/COP and other things. Smile

http://twitpic.com/2eqaz2

(if you're not following us on twitter you're missing a lot of updates. Just saying Smile )


Can't get to Twitter, Myspace, Facebook, Flickr etc from work. Websense evolved petty quickly once folks in the other building started hanging out tweeting all day....

Having the micro-controller in a quick-detachable format is a nice feature, though - if you manage to blow one up or mess up a flash write, a spare can be quickly substituted.

How compact is compact for the new form factor - Pacer or Isetta?

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Glad your internet filter thinks we're work related. Let's keep it that way Wink

The compact form factor allows boards of 3.15 x 2.5 inches. To fit our lovely new enclosures, here:
http://www.autosportlabs.org/blog/?p=1014


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