Fuel Injector Retrofit Project

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admin
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Posts: 44
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Re: Fuel Injector Retrofit Project

Post by admin » Sat Nov 17, 2018 12:00 am

Best guess at cost of replicating what I have done is between 5 and 7 hundred dollars. Depends on what parts/tools you already have and the luck you have in acquiring used parts and what prices you get on ebay and amazon.

Here is a list of minimum required parts

ITEM QTY COST COST EXT
Speeduino NO2C 1 159 159
Speeduino Full assembled 0 240 0
GM Intake Air Temperature Sensor  1 19.99 19.99
GM Engine Coolant Temp Sensor 0 16.95 0
16 GA Single Conductor Wire  1 29.95 29.95
Meterk Crimping Tool  1 13.97 13.97
580 Pcs Auto Electrical Connector  1 17.99 17.99
Nylon Equal Barb Tee 1 8.33 8.33
Nylon Equal 90 Degree Elbow 1 8.23 8.23
3/8" 10 Ft High Pressure Fuel Line 1 19.99 19.99
Used Fuelinjectors and rails 1 45 45
KE4BX 10 Piece Hose Clamp  3 1.99 5.97
 Electric EFI Fuel Pump Install Kit 1 17.99 17.99
Arduino Bluetooth Module (optional) 0 8.99 0
ATmega2560 ATMEGA16U2 1 14.99 14.99
Camshaft Position Sensor  1 8.95 8.95
Soldering Iron Kit 1 17.99 17.99
60/40 Tin Lead Solder 1 9.99 9.99
Standard Propane Fuel Cylinder 1 3.22 3.22
Steel Round Tube, 1.5" OD 1 16.83 16.83
Universal Straight Hose - 4" Length 4 9.12 36.48
Steel Hose Clamp (Pack of 10) 1 10.36 10.36
LSU 4.9 Wideband O2 Sensor,
Sigma Lambda Controller Free 2 1 145 145
Throttle body (salvage) 1 25 25
== 635.00

https://www.ebay.com/usr/speeduinoil?_t ... 2749.l2754
https://www.ebay.com/itm/Full-Assembled ... 3220049046
https://www.amazon.com/gp/product/B073R ... UTF8&psc=1
https://www.amazon.com/ACDelco-213-77-O ... ure+sensor
https://www.amazon.com/gp/product/B01JM ... FZSB&psc=1
https://www.amazon.com/gp/product/B06ZZ ... UTF8&psc=1
https://www.amazon.com/gp/product/B07BJ ... UTF8&psc=1
https://www.amazon.com/gp/product/B017U ... UTF8&psc=1
https://www.amazon.com/gp/product/B017V ... UTF8&psc=1
https://www.amazon.com/High-Pressure-Br ... +fuel+hose
seek and find.
https://www.amazon.com/gp/product/B00XA ... UTF8&psc=1
https://www.amazon.com/MOSTPLUS-Replace ... pump&psc=1
https://www.amazon.com/gp/product/B07C5 ... UTF8&psc=1
https://www.amazon.com/gp/product/B01H4 ... UTF8&psc=1
https://www.amazon.com/gp/product/B01K3 ... UTF8&psc=1
https://www.amazon.com/gp/product/B06XZ ... UTF8&psc=1
https://www.amazon.com/HGMZZQ-Solder-El ... rds=solder
https://www.amazon.com/Standard-Propane ... ane+bottle
https://www.amazon.com/gp/product/B007W ... UTF8&psc=1
https://www.amazon.com/Continental-Elit ... iator+hose

admin
Site Admin
Posts: 44
Joined: Mon Jul 02, 2018 1:02 am

Re: Fuel Injector Retrofit Project

Post by admin » Sat Nov 17, 2018 12:08 am

I think the second generation successor of this will cost much less. Second generation will be to retrofit a 1999 Kawasaki ZG1000 with fuel injectors.
In my mind I am thinking that the manifold construction will not be necessary. I will use the existing air-box for measuring the vacuum of the manifold.
I can place a throttle body on the airbox and mount injectors in a similar fashion as I did in the magna design but since the cylinders are in a straight line I dont think it will be necessary.

admin
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Posts: 44
Joined: Mon Jul 02, 2018 1:02 am

Re: Fuel Injector Retrofit Project

Post by admin » Sun Nov 18, 2018 12:29 am

I did get the trigger wheel in the mail today. He uses a plasma cutter to cut the wheel thus the ragged edges. The edges are rather ragged but it was a perfect fit. It bolted right up the the starter clutch. I will polish them off before attempting to get a pickup near it.
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admin
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Posts: 44
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Re: Fuel Injector Retrofit Project

Post by admin » Sun Nov 18, 2018 11:24 pm

today I was about to crack open the side cover to install my newly purchased trigger wheel and I thought I would give it one more try on seeing what crank information I could get from the alternator. . this time rather than measure from phase to phase I measured from one phase to chassis ground and wow!

I got a nice clean square wave output . I used the coil signal as sync and counted the pulses between coil firings and I get a rock steady 6 square waves between coil firings.

There are 18 poles on the alternator and 1 coil fires per rev. I am wondering if I combine detect the signals from all three phases and ground and combine them into a single signal what am I going to get? 18 Pulses per rev? ???Not sure at this moment what this means but I am excited to know that there is a crank signal that can be extracted from the alternator wires.
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admin
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Re: Fuel Injector Retrofit Project

Post by admin » Wed Nov 21, 2018 12:38 am

Trying to create a 5v square wave off the alternator. Not very successful. Built this simple circuit to get the 12 volts down to 5 volts.
Its 5 volts but full of noise and other weirdness. Signal from alternator is also full of weirdness.
Yellow trace is spark coil terminal. Blue is the 5 volts from this circuit.

https://youtu.be/5rRn7IMlo-s
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admin
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Re: Fuel Injector Retrofit Project

Post by admin » Wed Nov 21, 2018 1:39 am

Tightned up the connection from the circuit to the alternator and most of the noise went away but still variations of pulse size between pulses.

admin
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Posts: 44
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Re: Fuel Injector Retrofit Project

Post by admin » Thu Nov 22, 2018 5:31 pm

I am shocked. I just did some research on this alternator. The regulator is not what I would call a regulator at all. It senses the output voltage of the alternator and when it gets too big it uses an SCR to short it to ground. That's a bit crude but that's the way they do it. And that's probably why I am see a square wave instead of a sine wave. The SCRs are switching on and off. And the time they switch will vary with output voltage which varies with RPM. I don't have a chance of this working with such a system. So back to the drawing board. I took the side cover off the alternator side thinking there cant be any oil in there ...surprise, just enough oil to spoil my morning. But here is my next big genius idea. The rotor that holds the magnets is a drum about 1.5 inches wide and the side cover is made to fit over it. It's heavy and I think made of soft iron about 1/4 inch thick with the magnets mounted inside.. so how about mounting a VR sensor on the side cover and boring holes or cutting grooves into the outer side of the rotor/flywheel??? Comments please.
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admin
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Re: Fuel Injector Retrofit Project

Post by admin » Fri Nov 23, 2018 3:03 am

New Voltage regulator design if I decide to go that route.
But for now I am going to try to cut some "teeth" into the outside surface of the rotor drum.
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admin
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Re: Fuel Injector Retrofit Project

Post by admin » Mon Nov 26, 2018 1:39 am

This time it actually going to work.
I have two Flywheels they are identical except for the places where they were factory balanced. One is on the outside of the drum and the other is on the front of the drum.
I got the VR sensor mounted on the flywheel cover and the tip of the sensor is flush with the inside of the cover. I scoped it while cranking and the two holes drilled into the top of the drum are close enough to the tip of the sensor that I can see them both on each rev. And there solid and noiseless.

Next step drill 35 holes 10 degrees apart on the surface of the other flywheel I have. In the end I will have a 36 tooth with 1 missing tooth. To make sure they are directly under the sensor I will put the new flywheel on, remove the sensor and replace it with a black felt sharpie and crank a couple of times. That should show me exactly where the holes should be. I tried it on the existing flywheel and it leaves a black stripe around the circumference of the drum.

There is only about 2 threads holding the sleeve of the sensor to the cover so the JB-Weld is there for added strength and stability

I feel I am close to getting this crank timing issue solved.
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admin
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Re: Fuel Injector Retrofit Project

Post by admin » Fri Nov 30, 2018 11:42 pm

Finished the flywheel modification. Drilled 35 holes at 10 degrees intervals and skipped the 36th. Produced a 36-1 missing tooth trigger wheel.
Looking at the output signals it is very evident that I missed the mark on several of the holes and ended up putting some timing error into the waveforms. Bottom waveform is after drilling. the top waveform is after using the end-mill bit to flatten out the holes.
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