Turbocharging my F355 - Or how to remove any market value from your F355 remaining.

Really, they actually look amazing in there, once properly set back. I will have a little body work to do, but it looks really good even though I am still in the cutting, measuring, and fitting phase.

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Yes, I will be fixing and filling the bumper so it looks like stock again (perhaps with some metal trim).

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Symmetry is almost always good ... especially in women ...... using a normally aspirated header design for this system is also a good thing, as I assume you are not lowering the compression or changing cams? ..... the system as mentally configured so far, will generate manifold pressure ... what boost levels are you considering?

 

I only plan on running 10 psi on E85 with the system designed. I did consider changing compression, but E85 seemed like an easier answer. I am not going for ultimate power or trying to get crazy with things, I just wanted to build something fun, enjoyable, and in the end retain the things that I loved about the F355.

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10 PSI is quite a bit of boost .... single or twin intercoolers?

 

Haven't fully decided yet. Currently one, but I might add a second one, especially since it appears that I might have room for it now.

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Certainly ugly looking, just starting, so feel free to criticize. I now have a custom set of Fabspeed shorty headers.

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I kind of like how the plan is starting to come together.

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Looks like room for two intercoolers.


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Looking good so far

 

It all happens just a little bit at a time. Slow going, but only because work has been kicking my ass.

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Some times it's the little victories. This slim style quick release adapter fought valiantly but in the end lost to me and my lathe.

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Superb work! I think your paving the way for a long term update. Well done.

 

Little victories followed by big failures. ugh. I had all the pipes tacked up, and then my TIG welder dies, so I attempted to use my MIG welder, but that went poorly as well, not sure WTF happened as it was laying great beads the day before. Weird, yesterday was not my day.

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Well, at least I fixed the TIG welder.

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My muffler inlet is done along with the first part of the turbo down pipe. The welds could be prettier, but I never really learned how to weld, one day I will actually get serious about learning proper welding techniques. Unfortunately, I didn't even take shop class in high school.

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Turbocharger to Muffler downpipe done!

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The DP looks awesome Mark. Very cool.

 

routing looks good ....

 

Thanks guys!

So I was asked how a flex fuel sensor works the other day, I guessed that it measured electrical impedance through the fuel, but I was wrong, it was capacitance. I pinched the following from Clemson University's website:

"It is basically a cylindrical capacitor consisting of two tubes, the inner and outer electrode. The fuel flows through the gaps between. An AC voltage is applied to the electrodes. The relative permittivity of the fuel changes with the ethanol content, which leads to a change in the capacity accordingly. As the capacitance increases with increasing ethanol content, the oscillation frequency in the system will decrease and vice versa.

The analog frequency output is tied to a microprocessor which determines the capacitance by working backwards from the measured frequency. Due to the correlation between ethanol’s permittivity and the fluid’s temperature, the microprocessor corrects the capacitance for temperature variations in the fuel according to the output from an NTC (Negative Temperature Coefficient) thermistor. In addition, errors caused by the different conductivities of gasoline and ethanol are corrected.

The frequency of the single-wire output of the microprocessor to the ECM indicates the percentage of ethanol in the fuel. If required by the OEM the pulse width of the signal will indicate the fuel temperature."

So not all engine management systems are able to read this type of sensor output, but Megasquirt can. For others who need a 0-5v output, there is a company Zeitronix which makes a handy unit that converts the sensor output to a linear 0-5v output (link below).

Zeitronix ECA : SEMA Award Winning Ethanol Content Analyzer and Flex Fuel Sensor for E-85 and E-85/gasoline Blends

The flex fuel sensors are now much cheaper than they had been in the past, dropping from north of $350-600, down to $40, which is pretty reasonable.

Yesterday, most of my work was building the test bench for all the electronics. Pictures to follow as it gets closer to completion. I have built a small harness that connects the Megasquirt to a Jimstim with the expansion board for monitoring all the necessary outputs from the MS3-Pro. This will allow me to simulate a number of conditions to ensure that the digital dash and other CAN bus devices are all playing nicely with each other.

 

Mark just a question and indont recall you discussing this but if you put a new ecm in the car which i think you discussed you could add the ones with launch control and other goodies i think.

 

Yes, the ECU I am using has launch control... I doubt I will use it, as it seems to interfere with gnarly burnouts.

Basically, it (the MS3 pro) does all this:

MS3-Pro Features:

VE based tuning - supports Speed Density, Alpha-N, MAF based tuning & blended algorithms
Up to 12 sequential saturated fuel injector outputs
Up to 12 cylinder sequential support
Any unused injector outputs can be used as high current digital or PWM outputs
Up to 8 sequential logic level ignition outputs
Individual cylinder fuel & spark trim tables
Table Switching
VVT Control (4 channels)
Generic Wheel Decoder allows for support of nearly any trigger pattern.
Support for oddfire and evenfire engines
Internal SDCard high-speed data logging
Traction Control – Multiple Strategies
E85 flex fuel sensor input
Narrow and Wide Band O2 support
Long Term Fuel Trim -fuel trim to allow for changes in engine over time
High Power Time Enrichment -Allows for richer mixture after extended time in high power
Fully user configurable
Multiple Acceleration Enrichment Strategies
Staged Injection Control
Nitrous control strategies
Three-step rev limiter with flat shift
Trans Brake and Bump Box Control
Pit Lane Limiter - Can limit based on VSS or RPM if no VSS input is available
Rally style turbo anti-lag with rotational idle
Controls idle valve and configurable outputs for external fuel or air supply
Boost Control – Multiple open & closed loop strategies
Sequential shift spark cut
Solenoid output control for air shifter/drag application
Automatic shift point mode
Idle Control – Multiple open & closed loop strategies
Water and Methanol Injection
Fuel Pump Control
Intelligent Knock Detection and Response – 2 channels
Multiple Engine Protection and fault mode strategies
Spare analog inputs for external sensors
Supports standard automotive temperature or pressure sensors
Air Conditioner Control with feed-forward Idle-Up
Automatic compressor shutoff at programmable throttle position or RPM thresholds
Automatic cooling fan activation with A/C, user configurable
Cooling Fan Control
Programmable fan on and off activation points
Alternator Field Control/Voltage Regulation
Multiple open and closed loop strategies
Configurable voltage and temperature monitoring
Separate target voltages for afterstart, normal operation, over run, and WOT
Warning lamp output if voltage is above or below target
Comprehensive Test Modes - Outputs can be tested for on & off or PWM pulse functionality
Injector and spark disable mode, allows checking for suspected problematic cylinder by electronically preventing combustion event
CAN Support for I/O expansion – virtually limitless I/O capability!
CAN Support for 3rd party dash devices
Android Compatible
Self Calibration
No Dark Current!

 

So a little more about the engine control strategy that I have decided to employ. I wanted to use CANBus to communicate from the ECU to the digital dash. I think that this is really the key area that I am enhancing, ergonomics (which Ferrari did a fine job with in the 90's when the car hit the road). Technology has advanced to the point where I can actually improve upon the ergonomics in small ways. I really did wrestle with this one aspect of the car for quite some time, but I think that I accomplished what I wanted with regard to the cockpit and instrumentation. The Momo wheel, Racelogic IQ3s, Innovate WBO2, and Aerospace Logic gauges provide everything I wanted in a dash. I personally, like the look, but expect purists to hate it. I did really like the factory gauges, and there was nothing "wrong" with them either physically or aesthetically, but I think this will be equally appealing in the end. Functionally, I will be able to have much more information at my disposal, which I like and allows me to view critical parameters without having to wonder if I can trust the factory gauges.
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I have never allways agreed with the purists anyway. Plus its your car and a good oportunity to bring it up to modern standards. I think you could borrow alot of styles from the new ones.

I for one really like the 458 speciale center console with the placement of the buttons. If it was my car i would try to incorporate all the things you like about other more modern cars.

 

I was even looking for a steering wheel that would offer the buttons and function of the current cars short of a prince's ransom, but didn't find anything I really liked.

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Do you think you'll need heat shields for the intercoolers?

 

My problem would be i would want to do too many things and it would take so long i would be missing driving it.