Tuesday, September 1, 2020

Thursday, June 18, 2020

Onan injector test-efi retrofit

I'm using Yamaha YZF R6 injectors for the 6KW gasoline generator EFI retrofit.
This is a 2004 throttle body set to raid parts off of. Need two injectors, the wire harness connectors and the throttle position sensor.
Throttle position sensor with tamperproof fasteners- not for long ha
  Throttle position sensor and injectors in planned locations

North Omaha flow bench using mineral spirits and compressed air to maintain pressure.
250 ml graduated cylinders, a remote start button and a 12 volt power supply.
Spray pattern check, they seemed OK or at least the same.
Flow over time check, need to know this to get in the ball park for setup of the Megasquirt ecu. Flow was 127cc in 30 seconds at 43 psi. Checked out for matching reistance, all were about 11.5 ohms

Kiln control retrofit

Original control was two switches with high low off for each element. No temperature control at all. It required close watching.
  New control kit has two SSR's a type K thermocouple and a ramp and step control. From Amazon

Mostly installed, I put the SSR's low to keep them out of the heat and made a heat shield for the controller.
Thermocouple installed in the upper peep hole. Controller pulses SSR's to control heat input.

Thursday, February 27, 2020

EDM test with Dave and Roy

We build and test a low budget EDM for burning out broken taps, bolts and making holes in hard metals. Stepper motor control is an Arduino UNO set up for gap current control. This was steel
Test with aluminum. Hex hole burned with EDM. 35 -45 volts electrode positive
Redesign with a linear actuator for ram

Saturday, January 11, 2020

Copper chill weld repair

Our storage box for a Sioux seat grinder kit was missing the tab one one side to latch the top down. I didn't notice until I'd already painted the box. My plan was to use a copper chill to mask off what I didn't want wire feed weld to stick on and then the tab could be ground to fit. I used flattened copper tube for the chill.

Friday, December 20, 2019

Pi dash boot up- Raspberry Pi Tuner Studio dash on Megasquirt Goldbox

           Tuner Studio Autostart to a gauge display. Boot up about 1 minute
99 Dodge Dakota with a turbocharged 5.3 LS swap and 4l80e transmission
                                        Raspberry Pi B+ running tuner Studio
    Mausberry Circuits power supply with graceful shutdown upon ignition off

                              Megasquirt Goldbox xtra with transmission control
Raspberry Pi in a food container along with the Mausberry power supply

Tuesday, December 17, 2019

Manganese Steel Safe repair

I got this safe in the mid 80's and didn't get around to fixing the locks until 2019. It had been in a fire with the door open. We got it looking good and used it for fire proof record storage and that was good enough until now. It was made by the Manganese Steel Safe company in the 1920's by the serial numbers on the time lock movements. The metal is steel with around 14% manganese in it. It is non magnetic and tough to machine. High speed steel won't touch it and modern carbide is a slow process. Originally it was ground to fit. This turned out to be an issue trying to fit modern threaded stem dials on it.
Here it is when I picked it up. Took two of their forklifts to lift it.
It weighs 4,400 lbs by the scale at my work. Front axle 2,710 lbs rear 6,480 lbs
To unload it was hooked to my ash tree and I drove out from under it. My neighbor got a huge kick out that process. Then I dragged it into the garage and stood it up.
Here it is refinished but without the locks working. It was short one dial and the other was fubar. I looked for years for reasonably priced dials that fit on a square shank like the spindles on the locks had. I gave up
The door rotates to open kind of like an artillery breech. The are two bolts that keep the door from rotating when it is locked.
Lock plate with two combination locks covers removed and a three movement time lock. Either combination lock will open it and any time movement. Redundancy on these. Combo locks are indirect drive so drilling the spindles to get it open wouldn't do any good. Spindles are tapered and also made of Manganese steel. Pounding on tapered spindle would only make it tighter. These Yale time lock movements became kind of a standard. New movements are available in mechanical and electronic versions and would fit right in this case.
Back of lock plate pin on lever actuates dog clutch that operates bolt mechanism. Time locks inhibit the combo locks until they time out.
Dog clutch, spindles on inside of door
Combination lock spindles had a external square shank that the original dial fit on. We were missing one dial and the other was fubar. My plan was to adapt available modern dials with a 5/16x 40 threaded stem. To do this we drilled the original spindles partway with a 1/2" carbide spade bit and pressed in a piece of mild steel that could be drilled and tapped.
We got Sargent and Greenleaf dials which fit the original dial rings. Notice the spindle taper.
Checking for runout. The locks have a little adjustment for alignment and they turned out fine.
 These are four wheel locks with 100 million possible combinations based on a 100 division dial. The lever is gravity operated so no spring to give out.
I made a lever out of a crank by bending with heat and welding in an extension.
Locks fixed with new dials. Operation is locks set the dog clutch to operate the bolts by turning the crank then the lever rotates the door to open.
Covers not on the combo locks in this picture. The covers can only be removed and installed by another combination setting.

Thursday, August 22, 2019

Working on the tune

31% ethanol, water meth on at 4 psi, Got room to go up on boost. Notice the knock sensors show less on boost than vacuum.

Sunday, June 16, 2019

GMC's Onan gets a teflon fuel line

We replaced part of the Onan generator's fuel line with stainless braided teflon hose. Good for whatever ethanol gas that we use. Line was Fragola #4 p/n 360036.
Left is the original grommet and elbow that went in the bottom of the generator box. Right is a 1/4 NPT coupling welded in a plate to mount in the generator bottom box. I used steel JIC fittings not aluminum AN stuff.
Original fuel pass through.

Sunday, November 25, 2018

Cam signal simulator, Arduino Nano, 1999 JTEC

Getting the factory tach to work with an LS engine swap

Arduino IDE-

//Cam signal simulator

/*Goal is to provide a cam signal to a JTEC equipped 1999 Dodge Dakota to make the dash tach guage ​
 * work and make JETC think the engine is running. This JTEC seems to need a evenly spaced 8 pulse crank signal ​
 * and a cam signal that changes state every 180 degrees rotation of the cam. Also added a inverted cam signal output ​
 * which can be used in case there is a correlation issue with the JTEC. crank input D2, output on D6 and D12 */​
  int state=LOW;​
  int lastState=LOW;​
  int count=0;​
void setup() {​
  // put your setup code here, to run once:​
  pinMode(2, INPUT);​
  pinMode(13, OUTPUT);​
  pinMode(12, OUTPUT);​
  pinMode(6, OUTPUT);​
  state = digitalRead(2);​
  digitalWrite(13, HIGH);​
  digitalWrite(12, LOW);​
  digitalWrite(6, HIGH);​
void loop() {​
  // put your main code here, to run repeatedly:​
  if (state == HIGH && lastState == LOW) {​
  if (count <= 7) digitalWrite(13,HIGH),digitalWrite(12,LOW),digitalWrite(6,HIGH);​
  if (count >= 8) digitalWrite(13,LOW),digitalWrite(12,HIGH),digitalWrite(6,LOW);​
  if (count >= 15) count=0;​

Wednesday, October 24, 2018

Dodge Dakota repower

5.3 LS, 78/75 turbo Elgin sloppy stage 2 cam, Warr 102 mm throttle. Tial copy 60 mm wastegate. Megasquirt Goldbox Xtra ECU with transmission control, 4L80e with Jakes converter.