Aijii's EJ207 JDM V10, EFR7163, Flex Fuel 2008 STI

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 11:23 am

Obligatory pussy shot. Cat inspected the work, approves. Note the ghetto overflow/expansion tank lid (i used a juice container). Still need to find a spot and a proper overflow tank.
2016-01-06 20.09.26.jpg
2016-01-06 20.09.26.jpg (163.09 KiB) Viewed 2686 times

2016-01-06 20.10.34.jpg
2016-01-06 20.10.34.jpg (188.22 KiB) Viewed 2686 times
2016-01-06 20.13.43.jpg
2016-01-06 20.13.43.jpg (80.31 KiB) Viewed 2686 times

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Merpmod/Flex Fuel

Postby aijii » Sun Feb 28, 2016 7:19 pm

So about this time I probably should talk about Merpmod.

Merpmod, according to google is a modification of a middle earth role playing game. Wrong Merpmod. What i'm talking about is a hack of the 32-bit Denso ECU (originally a USDM06 WRX but since ported in various levels of completeness across to other ROMs) that set out to introduce features such as Launch Control, Flat foot shifting and speed density to the newer 32 bit ROMs. The 16 bit guys had this already with carberry.

After a while, the project then got newer stuff like CEL flashing for knock, EGT, ECT, IAM etc and 3 x 2 map switching and blending. The latter was the first piece of the flex fuel puzzle, but this is pretty much where development stopped. Merp grew up and got busy it seems haha.

Not content with continually throwing donations at a paypal account to no avail, I decided to pick up where Merp left off with his work. Quite a few areas still needed to be addressed and in November 2015 I had a build ready to flash onto the car.

Rexmas so me take a few laps around Sandown at a time with increasingly more ethanol in the tank each time. Warwick and I checked logs and trims - and bam... it seemed to be working.

January 8th 2016 saw me spend a day up at Ballarat getting Warwick to do the beginnings of a flex fuel tune with the new patch, everything went to plan. There are now at least 2 2008 STIs driving around Melbourne with my custom build of Merpmod, and another few cars in South Africa.

After many very late nights spent coding, release candidate 1 adds a sheet load more functionality, such as wideband input (initially for lean-boost alarm and failsafe), fuel pressure sensor input (pressure delta alarm/failsafe) and a bunch of other stuff I still need to test.

Happy days so far..

User avatar
ABSTI
Impreza RS Driver
Posts: 165
Joined: Wed Jun 25, 2014 7:12 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby ABSTI » Sun Mar 06, 2016 8:47 am

Very nice write up!

User avatar
turboshift
Impreza WRX Driver
Posts: 495
Joined: Sun Sep 02, 2012 9:17 pm
Location: Canberra, ACT

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby turboshift » Sun Mar 06, 2016 9:59 am

Software developer by trade or just got the want for it? You have done some impressive work by the sounds of it! Congratulations!


Sent from my iPhone using Tapatalk

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sat Mar 12, 2016 10:51 am

Thanks :) network engineer/consultant, did software as part of engineering degree and have been a hack ever since haha

bigBADbenny
Impreza RS Driver
Posts: 209
Joined: Tue Mar 20, 2012 11:43 am

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby bigBADbenny » Sun Mar 13, 2016 6:01 pm

Wow such fortitude and endeavour :)
What's the completion date for the Aijii/Shadowtuned flex fuel tune and will it be commercially available?

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Mon Apr 04, 2016 10:52 pm

Cheers!

There is no completion date per se. I've ran a development build on the car since November, I basically eat my own dog food in that sense. Warwick has had an early test build that he's run up on a couple of cars I think, also MSR up in Sydney has tuned with the early November build.

So the base Merpmod "Switch" build, as provided by Merpmod does:

* Launch Control (Compensated timing/fuel, locked timing/fuel not implemented)
* Flat Foot Shifting (Static and Auto, based on gear ratios) <- I'm still toying with auto mode, don't have it set up right yet
* Speed Density
* Check Engine Light Flashing on a handful of error codes
* 3 x 2 Map switching and blending, controllable via si-drive and/or TGV inputs. Timing, Boost and Primary Open Loop Fueling, with an injector scalar multiplier that follows eth content. Enough for basic flex but not enough for me ;)

My early November 2015 build added:
* Failsafe on flex sensor input to work with the Blueflex stuff with CEL flash if sensor out of range
* Different blend curves for boost/timing/fuel/speed-density
* Cranking/Tipin/Startup enrichment blending multiplier tables

I've not got a "Release Candidate" build out for testing now with those guys, I've made 3 revisions of it so far mainly due to bugs I've hit. There is a sheet load more functionality in RC1.3:
12694907_10153350012821935_8081276442666193109_o.jpg
12694907_10153350012821935_8081276442666193109_o.jpg (255.99 KiB) Viewed 2449 times

12640231_10153350013086935_3728066905794583399_o.jpg
12640231_10153350013086935_3728066905794583399_o.jpg (213.48 KiB) Viewed 2449 times

* Revamped Definitions layout, easier to follow categorisation.
* Reworked the way inputs are polled/updated to be more modular for future expansion of code
* Added Rear o2 input option
* Added MAF input option (for full SD cars)
* Overhauled the CEL Flashing code. There is now a failsafe function that runs regularly that checks all the various failsafe triggers and set flags for each one. Again boring, but more modular for future expansion. Needed to do this for the next bit
* added failsafe fueling additive function, with switches for various trigger conditions (EGT, severe knock, Lean boost, ECT). I was going to make this a multiplier, but it just adds a fixed additive whilst any trigger condition is active. I may consider adding a decay value to decay away the extra fuel slowly after the trigger condition goes away, but CBF. tell me if you think it's needed.
* Added dual blended MAF scaling tables for CL fueling tweaks, and added options to the MAF Mode table to select dual blended MAFs for full MAF mode, or blended MAF/SD mode.
* Added dual blended front O2 scaling tables for CL fueling tweaks
* Changed from fixed blend curves for boost, timing, fuel and SD to 4 selectable blend curves for OL Fueling, CL Fueling,Base Timing, Knock Control (KCR), WG, Boost, MAF and Speed Density Tables (multiplier tables such as injector scaling, cranking fuel, tip-in and startup enrich will always follow the master blend ratio), i.e. carberry-esque
* added an ECU calculated Injector Duty Cycle parameter (loggable, hopefully more accurate than RR post calculated value), and added a failsafe trigger and corresponding CEL flash failsafe action if above a threshold
* added wideband sensor capability off any of the currently defined inputs
* added lean boost failsafe trigger. Not sure if I should add a WGDC limiter or just switch to the valet WGDC/Boost tables as an additional failsafe action... I might actually add that, should be simple enough. EDIT - just added. selectable for a bunch of triggers to set the valet mode flag, quick and dirty way but there are already merpmod valet mode WG and TB tables... why recreate the wheel
* added fuel pressure sensor capability off any input
* added fuel pressure delta calculation (loggable) and failsafe trigger if above a threshold

I think I'll leave RC1.3 where it is. Just want to get it tested properly on a dyno and running on a couple of friend's cars locally before it's called official. Talk to Shadow Tuned/Warwick/GotitRex in Melbourne or MSR if you're in Sydney for more info at this stage. Tuning will be through those guys initially.

mikes
Blue MY08 WRX Driver
Blue MY08 WRX Driver
Posts: 4190
Joined: Tue Jul 25, 2006 6:12 pm
Location: Melbourne

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby mikes » Tue Apr 05, 2016 6:29 pm

oh my gawd. merpmod is a mod of a middle earth rpg?!? mind blown
MY08 WRX

bigBADbenny
Impreza RS Driver
Posts: 209
Joined: Tue Mar 20, 2012 11:43 am

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby bigBADbenny » Wed Apr 06, 2016 3:21 pm

Love it. What are the hardware requirements/options for fully utilising this tune?
Eg specifically
flex fuel sensor
Maf vs map and what sensor used if map
I'm building a spare ej255 and will have time to add upgraded fueling, turbo, tmic etc and going the extra steps re this tune is looking plausible.

User avatar
Kristian
Social Committee Kristian
Social Committee Kristian
Posts: 510
Joined: Fri Sep 03, 2010 10:21 am
Location: Melbourne

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby Kristian » Mon Apr 11, 2016 5:28 pm

Image
------------------ GOT IT REX TUNED 2011 STI SEDAN ------------------

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 4:44 pm

A fair bit has happened car wise since I've been here last.

I'll try to hit it all in order.

This pic was taken in Feb 2016... I like it. So much has changed since then...
IMAG0713.jpg
IMAG0713.jpg (145.81 KiB) Viewed 1230 times
Last edited by aijii on Sun Aug 20, 2017 9:44 pm, edited 6 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 9:22 pm

God Damned Lean Out Issue
I'll save you the TLDR;

* Ryco make a drop in replacement fuel filter for the GR style in-tank MRA fuel sender
* I replaced my fuel filter with one and shortly after noticed my car was leaning out under full load
* The fuel filter was the last thing I checked because I figured it was brand new. After changing pretty much everything but the fuel rails (I threw ID1300s in at this time) I pulled my hair out.. almost.
* I looked back at the fuel filter and found that it had swelled really badly, the filter was pretty much completely clogged. So I hacked the in-tank MRA and ran a line from the pump straight to the top of the bulkhead barb. Adopted a GD style engine bay filter and the lean out issue gone.. almost
* I found that the alternator was contributing to this - in that the ECU was actually commanding the alternator to shut off during WOT. It apparently is a thing, but I didn't like it as a multimeter was showing pretty pathetic voltage across the fuel pump under WOT whenever this happened.
* A bit of ECU hacking with the help of td-d from Romraider and we found that its easy to bypass this in software. So now the alternator stays on, probably costing a bit of power up top but the AFRs are much happier now.
IMAG1016.jpg
IMAG1016.jpg (122.13 KiB) Viewed 1231 times

IMAG1018.jpg
IMAG1018.jpg (188 KiB) Viewed 1231 times
Last edited by aijii on Sun Aug 20, 2017 9:37 pm, edited 1 time in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 9:22 pm

Dyno Tune Time
Car made 291KW at 24PSI on the GIR Dyno Dynamics dyno in June 2016. Good times.
IMAG1054.jpg
IMAG1054.jpg (81.67 KiB) Viewed 1225 times


Needed a new set of plugs and coil packs though as it was missing under heavy load... thanks to the GIR boys for sorting me out on the dyno (leather hands, changing plugs and coils on a hot engine!!)

IMAG1057.jpg
IMAG1057.jpg (64.83 KiB) Viewed 1228 times


Plugs seemed to read a bit.. fouled ? Engine didn't seem to be running the best ... however aside of consuming a bit of oil, saw me through Subinats 2016 and I got a 1:58 on my first time at Phillip Island, 3rd time on a track, with no real idea what I'm doing. Was quite chuffed with the effort.

IMAG1102.jpg
IMAG1102.jpg (147.87 KiB) Viewed 1228 times
Last edited by aijii on Sun Aug 20, 2017 9:53 pm, edited 4 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 9:23 pm

Sway Bars
Whiteline adjustable sway bars front and rear - scored these for cheaps and a swap of my OEM rear bar with a friend who needed to put the originals back on. Apparently stiff sways and suspension isn't the best for good track times..

Install went fairly smoothly except for Slabs farting under the car and me stripping one of the captive nuts that hold the front sway bar bushings in. Off to Ben at RCM to helicoil and was all good.

Car feels positively better with the new setup, although it took a while to get used to the increased tram-lining...

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 9:23 pm

CANBus controlled Active Exhaust Butterlfy
in the meantime I got the guys down at auto access in Coburg to hack into my Hi-Tech exhaust system to install an inline, active exhaust sytems vacuum controlled butterfly valve.
http://www.activeexhaustsystems.com.au/index.php?option=com_content&view=article&id=104&Itemid=258

This valve sits in-line and silences the exhaust by creating back pressure - it never fully closes, it has an adjustable closed position. Vacuum holds it shut - so it doesn't rattle around or blow open like some of the boost operated or electric systems can.

I had been working on an Arduino project that hooked into the CAnbus and controlled a 3 port MAC valve with a goal to have control of the valve completely integrated with SIdrive, throttle etc. End result - quiet exhaust in I and S mode unless I put my foot down, and loud exhaust in s#. Great.

Need to get some proper pics of the setup next time it is up on jack stands..
Last edited by aijii on Sun Aug 20, 2017 10:06 pm, edited 5 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 9:24 pm

Tail-light overlays, side-skirts
Got a few cosmetic things done to the car... Tail-light overlays went on, got butchered, and went on a second time. What a pain in the butt.

Also got a used set of ultrex side skirts... and an ultrex rear diffuser for a bargain!

IMG_20170219_164814.jpg
IMG_20170219_164814.jpg (46.53 KiB) Viewed 1218 times
IMG_20170303_223829.jpg
IMG_20170303_223829.jpg (108.65 KiB) Viewed 1217 times
IMG_20170303_223841.jpg
IMG_20170303_223841.jpg (83.87 KiB) Viewed 1217 times
Last edited by aijii on Sun Aug 20, 2017 10:07 pm, edited 3 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 9:24 pm

New Engine - EJ 207 Goodness
I was lucky enough to get my hands on a JDM EJ207 V10/W20 long motor in need of a rebuild. These things are stout, with the 13.5mm thick cylinder walls the cams are great for a stock car (had them measured, exhaust side is 10.4mm and 264 duration) and the heads are amazing.

I was a little concerned around losing .5 litre of displacement... I looked into getting the thing stroked to 2.1L but wasn't convinced the trade off in VE shift to the left was going to help me in my quest for a nice redline.

Anyway I had the thing built by Phil Lowe, with GIR helping out with sourcing various bits and pieces needed at the last minute.

New Engine build specs:

Wossner EJ207 8:1 Pistons
Cosworth Rods
ARP 625 Head Studs
New 75mm double crossed drilled nitrated crank
King .005 o/d main bearing shells
ACL race big end bearings
Kelford KVS109 valve springs
RCM head-gaskets *ej207 v10*
Full head recondition (needed a few valve seats cut)
Killer B Oil Pan, Pickup and Windage Tray
Competition Stage 2 Clutch and Lightweight Flywheel
Full rotating assembly balance
Line-honed to get the tunnel nice and true again *the mains were out some*

image (1).jpg
image (1).jpg (67.89 KiB) Viewed 1215 times
image.jpg
image.jpg (84.27 KiB) Viewed 1215 times


The engine was built in April 2017 and sat around at a friends factory for a few months... Phil couldn't believe how smoothly the crank turned - with pistons installed the crank can be turned by hand which is not particularly common apparently.
Last edited by aijii on Sun Aug 20, 2017 10:13 pm, edited 2 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 10:04 pm

New Turbo Setup
So the engine was coming out soon - so I decided that the car may as well get a turbo upgrade as well. Maximise use of the engine out time...

IMG_20170505_112444.jpg
IMG_20170505_112444.jpg (85.57 KiB) Viewed 1214 times


So whilst I was waiting for a suitable weekend to do the engine swap, I had Havoc Engineering fabricate up a twist mount/rotated up-pipe and down-pipe to suit a Borg Warner EFR 7163 single scroll turbo.

IMG_20170526_153650.jpg
IMG_20170526_153650.jpg (143.43 KiB) Viewed 1214 times


The cool thing about the EFR is the inbuilt IWG and BPV simplified the plumbing hugely. Plus not to mention the super short shot straight into the AWIC, which is now flipped over. I had Havoc add a raised filler neck to the AWIC core to serve as a combined bleed/fill point for the system. Also ditched the reservoir...

IMG_20170526_154849.jpg
IMG_20170526_154849.jpg (131.69 KiB) Viewed 1214 times
Last edited by aijii on Sun Aug 20, 2017 10:28 pm, edited 2 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 10:05 pm

The car with the 7163 on the 2.5L was very fun to drive - it hit every bit as hard as the dom2.5, came on earlier, which was amazing considering it flows over 10lb/min more than the blouch! That's without trying to tune it.

I fitted a Turbosmart dual port IWG-75 (thanks Kenny!), 4 Port EBCS (thanks Kenny!) and a Turbosmart BPV (I gave the plastic borg BPV a go, it dosed all the time and made lots of noise at cruise. Didn't sound right).

I had to steal a few bits from the Blouch - namely the oil feed line and water feed line. I had the oil drain and water return donated to me (thanks Kenny!).

IMG_20170527_223821.jpg
IMG_20170527_223821.jpg (137.84 KiB) Viewed 1213 times


IMG_20170527_183057.jpg
IMG_20170527_183057.jpg (89.66 KiB) Viewed 1213 times


IMG_20170601_145534.jpg
IMG_20170601_145534.jpg (152.51 KiB) Viewed 1213 times


Was getting very excited - engine swap weekend was fast arriving, targeting the last weekend of July 2017.. more to come..

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: Aijii's Open-Source Flex Fuel 2008 STI, Dom 2.5XTR, AWIC and Stuff

Postby aijii » Sun Aug 20, 2017 10:32 pm

One of these engines is smaller than the other, but they're both the same size...
IMG_20170729_141838.jpg
IMG_20170729_141838.jpg (144.3 KiB) Viewed 1211 times


IMG_20170729_144139.jpg
IMG_20170729_144139.jpg (132.47 KiB) Viewed 1211 times


don't drop anything in there..
IMG_20170729_144153.jpg
IMG_20170729_144153.jpg (126.37 KiB) Viewed 1211 times
Last edited by aijii on Sun Aug 20, 2017 10:37 pm, edited 1 time in total.

Return to “Photo Gallery and Build Threads”

Who is online

Users browsing this forum: No registered users and 10 guests