Micro controlled VNT project

[regcheeseman]

The VNT controller servo is now responding to servo feedback and throttle position.


As a fair few people have suggested it, I've written the code in for a shift light.

Meanwhile, back in the workshop, the proper engineering carries on....

Front end, my IC fun wasn't completely wasted. Shame about the dog poo bags!


One manky gearbox tidied up


Block well on the way (WAITING FOR GIRDLE!!!!!)


Marked up the manifolds for some port matching and a bit of flow work.


Finally - toys. mmmmwahahahahahahahahahahaha 

1Y/AAZ head, 1Y manifold, MK4 VNT turbo, MLS gasket, ARP studs

I've been painting more bits this evening and putting a few bits together, then I got the carbide burrs out and the hacksaw and ruined my manifold....

Don't worry all will be fine!

[theman53]

IDK if the mani is as tough as the D24 that I ported, but if so good job. The 1.6L TD intake was like butter compared to the D24. Looks great keep up the good work.

[regcheeseman]

Started to attack my ports with a carbide burr in a drill (gave up on the die grinder and the dremel)
Was taking ages, then I found a milling cutter and whacked that in the drill - that sorted it!

Then I got a abrasive disc in my grinder and sorted that inlet manifold out - just have to get the holes welded up.

[lord_verminaard]

Updates??? 

Brendan

[erice1984]

I think BlueMule might have been confused, Turbos are load dependent not RPM dependent.

[regcheeseman]

not a massive amount to update really, but the project has changed a lot, I've tested the mark one PCB as far as it will go and to be honest am not happy.

Mark two has been designed and coded and now I'm on mk 3 using different technology to improve the inputs and the speed. I've ditched the complex config mode and implemented a shift light.
I've lost the multi stage boost limits and switched to a simpler single 'power factor' which shifts the boost map up or down.

This streamlines the code with no detrimental effect on functionality

I've also designed the adaptor to run the mk1 speedo from an electronic gearbox pick-up

Meanwhile the car got painted, the paint reacted, was stripped and is ready for re-painting.

Oh and I also swapped my daily from a ford to a VW - and then modified that.

When I get some real usable results or pictures, you will know!

[monomer]

Reg,


Besides the controller, can you give off a parts list of the turbo, actuator and the like?


I'm just looking at going turbo and I'm going to go straight for this!

[regcheeseman]

The turbo is a BV?39 I think - from a mk4 golf

The actuator is a power valve assembly from an NSR 250 - with custom made fitting at the turbo end, actuation is remote via bowden cables

TPS sensor is just a quality potentiometer attached to the accelerator pedal

The system I'm designing should have enough adjustability to work with any VNT.

[regcheeseman]

And the prize for the most over engineered throttle position sensor......



I originally stuck the sensor on the throttle pedal shaft but only got 30 degrees of rotation which would give poor resolution so I messed around with cogs and gears and the found a drive mech from a drug infusion pump going for scrap.

transfers the 30 degrees to nearly the 270 of the sensor - the rest is compensated for by electronic wizardy.

[VW_Commuter]

And the prize for the most over engineered throttle position sensor......



I originally stuck the sensor on the throttle pedal shaft but only got 30 degrees of rotation which would give poor resolution so I messed around with cogs and gears and the found a drive mech from a drug infusion pump going for scrap.

transfers the 30 degrees to nearly the 270 of the sensor - the rest is compensated for by electronic wizardy.

That is sooooo cool.

[tomnik]

Hi,

regcheeseman, will your VNT controller be available to buy (as a complete set or parts and code)?
Did you get it to a final version?

Tom

[regcheeseman]

I'm intending to make five boards, four to sell, I will also bundle notes, schematics, PCB artwork, parts listings, Microprocessor code etc into a package for free.

I'm not quite at that stage yet. The second revision of the board was taken to the developers last week.


Hopefully have it working properly in the new year.

[Baxter]

Do you have a bird? you have way too much time on your hands...
 
Well done so far, smart arse...
 

[Alcaid]

These two PCBs are around the same size as an EDC15 ECU. Maybe a bit over engineered for the simple job it is going to do? 

[theman53]

I would want you to sell these eventhough I don't have a VNT yet. I think I love you a little...no homo