7875 + 5.9 + E85 + Megasquirt

Forced Induction Mopar

  1. subcom

    subcom Well-Known Member

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    Since my current build has diverged so far from my original thread, I'm going to start a new one to help me keep better track of my progress/setbacks. For background on my previous 5.9/Turbo build, see here. TL;DR - stock bottom end 5.9, EQ OTS heads, Fitech, E85 ran a best of 6.90/105MPH in the 1/8th.

    New build:
    -1994 5.9 Magnum, EQ heads, stock crank, forged Wiseco 10.5:1 pistons and SCAT rods, custom ground cam from Oregon Camshaft. 727 with RMVB, narrowed and back-braced 8.75 with 3.23s suregrip, minitub. Platform is the 65 Valiant Signet in my profile. Car is about 3k lbs without me in it.
    -Turbo is a china billet wheel 7875 with the smaller .96 A/R, 3" downpipe to dual 2.5" exhaust with dumps. 2" mild steel hotside and 50mm wastegate.
    -Fuel/Spark is an Edelbrock MPI intake, 84LB Decapped Chevy Flex 5.3L V8 injectors, AEM 380LPH pump, LS 90mm Throttle Body, LS D585 Coils, factory magnum distributor for cam sync, all being driven by a MS3PRO EVO ECU.
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    Last edited: Dec 5, 2020
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    • pishta

      pishta I know I'm right....

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      cool MS build! Ill follow just because I need to get off my ass on my MS2 build . What are those injectors off? 84lb!!! is that because they are 'decapped' and dont run a spray pattern?
       
    • subcom

      subcom Well-Known Member

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      Factory Chevy/GMC Truck/Van Flex 5.3L V8 Fuel Injectors Denso EV6. I don't have the part number but I bought them already decapped and flowed with flow sheet from an Ebay vendor.
       
    • subcom

      subcom Well-Known Member

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      The MS3PRO has been great so far. I've had a couple of bugs and am still working thru the tune but it's getting closer. I burned probably 8 gallons of E85 just sitting in the driveway trying to get it to idle. I have my VE table, AFR, Timing table basically where I want it and have taken the car out for some lite-load cruising using the autotune feature of TunerStudio. It works great and within about 5 miles of driving the car is idling great, comes off idle and accelerates great, cruises close to my target AFRs. Hot and cold starts are immediate. This particular model has all kinds of bells and whistles I still need to enable and test before going "full tilt boogie". I wired up meth injection control yesterday. I'm using it as a simple on/off and not staged or ramped but even so it has granular tunability for when to enable it;
      Screen Shot 2020-12-05 at 11.24.54 AM.png
       
    • subcom

      subcom Well-Known Member

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      And my next rainy day project will be a touchscreen dash to compliment my analog gauges.
      raspbpi-7inch-touchscreen.JPG
       
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      • pishta

        pishta I know I'm right....

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        MY MS2 is ancient compared to that but still better than the MS1. Keep on it!
         
      • subcom

        subcom Well-Known Member

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        ms3 is installed on the pass side kick panel. I still have some clean-up to do. I used a lot of crimp connections inside, but everything under the hood I took my time and tinned all wires, soldered all connections and sealed with heat shrink tube, tape and/or wire loom. So far, that's been the most time consuming part of this project.
        ms3pro-install.JPG
         
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        • pishta

          pishta I know I'm right....

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          I think I'm gonna mount it in the glove box on a board as I never put stuff in there anyway 'cept the registration.
           
        • J Glenn

          J Glenn FABO Gold Member FABO Gold Member

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          I'm very interested in seeing that. I do allot with the raspberry pi, I own several of those touch-screens. They are nice. I'm *just* starting megasquirt. (Literally today I got my first sensor, a temp sensor I had lying around hooked-up and "calibrated".)
           
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          • TT5.9mag

            TT5.9mag Two atmospheres are better than one

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            Following. Nice work on the new mill. The engine bay looks awesome. On E85 do you think your fuel pump and 84 lb injectors are going to be enough? I’m guessing you’ll find limit of duty cycle on those injectors pretty quick.
             
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            • subcom

              subcom Well-Known Member

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              As usual, you ask me the tough questions that make me doubt my decisions...lol...but I honestly appreciate it.
              I *think* I might be close on the injectors but with a goal of 650 FWHP I might be pushing it also. At that point my options would be to go bigger, dilute the E85 to E70 or similar, or maybe spray more meth. The injectors flowed at 38lb/hr at 58psi and 50% duty cycle at 5000rpm according to the shop I bought them from. I'm not sure if they scale linearly (100% duty = 76lb/hr?) or not, but looking at my log from earlier today where I hit about 7psi of boost, Megalogviewer seems to back up that 38lb/hr flow rate...if I did the math right and the numbers are accurate.
              injector_flow.JPG Screen Shot 2020-12-06 at 5.53.02 PM.png
               
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              • subcom

                subcom Well-Known Member

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                I got the os loaded, java dependencies installed and installed the TunerStudio package. Was pretty easy. The screen is tiny! but I think it will work decent displaying just a few critical gauges; AFR, RPM, Boost...
                The challenge will be powering it from the car. Actually that is the easy part, it will be gracefully powering it down when going key off or similar to not corrupt the os. I think this can be done over the GPIO pins.
                 
              • pishta

                pishta I know I'm right....

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                The most those injectors can flow is 64lbs. You can't (shouldnt) go past 85% duty cycle of any injector as they go 'static' ie. don't close. You can increase the fuel pressure to scale up the output. Going huge on the injectors (ie. WRX injectors) also is not good on the idle quality, sort of a balancing act, but a very broad range.
                 
              • J Glenn

                J Glenn FABO Gold Member FABO Gold Member

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                Wow. That's cool. You have bad power (the lighting bolt). Those screens take some juice as does the pi. The power-supplies (plugged into the wall) have been the biggest challenge in using those screens. You might want to power a (fused) 12V to 5V regulator directly from a switched battery connection, that way you can turn it on an off independent of the ignition to avoid bad power-up/down. And (I think) you can power it directly using the GPIO, bypassing the on-board regulator -- I do that for Arduino all the time, but I'm not sure if I've ever done it with a Pi.)

                HALT: I use the adafruit code for an 'off' button from one of the GPIO pins. (sudo git clone git://github.com/adafruit/Adafruit-GPIO-Halt). Easy as pi:-/

                Are you planning to strip down the OS to run ONLY the necessary code?

                Aside from the power-up down & boot-up complexity, the next issue you'll eventually run into is that those pi's don't last forever. Eventually it will probably fail. (I've probably owned at least 100 pi's, I teach kids linux as a hobby. Failures are not that uncommon.)
                 
                Last edited: Dec 7, 2020
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                • turboking15

                  turboking15 Well-Known Member

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                  What alternator are you running?
                   
                • pishta

                  pishta I know I'm right....

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                  Awesome, someone we can talk to about wonky bluetooth in linux! Ha, Ill do that offline. Still subscribed!
                   
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                  • J Glenn

                    J Glenn FABO Gold Member FABO Gold Member

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                    ha... ya... I've tried the bluetooth a couple times... 'nuff said.
                     
                  • TT5.9mag

                    TT5.9mag Two atmospheres are better than one

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                    I plugged 650whp and e85 in to fiveomotorsports.com sizing calculator and it spit out this...
                    1849B803-FE77-4C8B-B0B7-85199E72BE08.png
                    Bottom right. Turbocharged on e85 they recommend a 93lb/hr injector. My rule of thumb is when I think I have enough fuel pump or injector, I double it. I use their (five o) 1000cc injectors on my Honda j35 and they idle like stock and flow a ton. Just food for thought. Watch the duty cycle and the AFR and if you run up against the limit it’s easy to swap em out later.
                     
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                    • subcom

                      subcom Well-Known Member

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                      110amp i believe, mini Denso. Part number from an old Toyota 4Runner as I recall.
                       
                    • subcom

                      subcom Well-Known Member

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                      This was just powering from my MacBook USB. The on/off switch in the car would be easiest approach. I like that. I haven’t really put much thought into long term for the Pi about stripping it down but it occurred to me I could mount the OS read-only and write logs to an external USB stick to avoid any sudden pwr loss issues.
                      Linux has been my bread and butter for 20 years and I owned an embedded electronics firm (mostly fpga, some embedded Linux and rtos) for 10 years. Adding a Pi and Megasquirt to my old Mopar is a nerd match made in heaven for me. Lol.
                       
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                      • turbovan

                        turbovan Well-Known Member

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                        I absolutely love the direction of this new thread! Great work on your setup and thank you for all the posts and updates!
                        I copied your initial setup(blow through), and my first startup was yesterday.

                        Super curious to see how the new turbo spools vs the gt45. As for injectors I believe it was already suggested that you could raise your base fuel pressure to compensate for flow especially since I haven’t seen you push much boost yet. I’m coming from the Wrx world and I’ve ran 70psi base pressure on ID1000 injectors with 30psi on top of it. Idle quality was great.

                        Any plans for an intercooler in the future?
                         
                        Last edited: Dec 8, 2020
                      • subcom

                        subcom Well-Known Member

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                        Good luck with your build. You'll love the GT45. It really is a beast of a turbo for the price. I've thought about an intercooler, but I'm running out of room in this little Early A. I'd have to carry it in my lap in the driver's seat at this point. Lol.
                         
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                        • TT5.9mag

                          TT5.9mag Two atmospheres are better than one

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                          Is your 7875 from VS? I just got my hands on a VS7875 gen 2 with the billet wheel and I gotta say I’m pretty impressed with the quality just by looking at it.
                           
                        • subcom

                          subcom Well-Known Member

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                          Mine is a non-branded Ebay one. By all appearances it's the same as the VSR one. VSR also has a version with a larger hot (1.25 I believe) A/R side and 4" exhaust. Mine is 0.96 with 3" and undivided T4.
                           
                        • TT5.9mag

                          TT5.9mag Two atmospheres are better than one

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                          Yup mine is the 1.25 divided T4 and a 4” v band outlet.
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                          Kinda funny a friend of mine called me and said he won it in a raffle and asked if I wanted it. I had no use for it at that point but he only wanted $300 so I bought it.
                           
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