Wednesday, 15 April 2015

Work on the next project commencing

Over the weekend I got to start some work on the next project I'm starting. This is the car one. The plan is to turbocharge my mate's 2001 Ford Falcon AU II 4.0L inline 6. The first step in this process is going to be replacing the stock ECU with a custom DIY one, most likely rusEfi. So we went out to my "donor" car that I rolled a few years ago.
It isn't in particularly good shape, but before water got in it too badly it would run. However now the excellent smartshield immobiliser system is working (BEM and ECU or Key Barrel aren't talking I think) and won't let us even turn it over. We headed out to this in an attempt to get the diff out so we can weld it up and make it "Locked" rather than an "Open" diff. That didn't work because we realised that to get the centre of the diff out we would need to remove the entire back axle assembly.

As you can see the outside of the diff was fairly dirty and the muck made it a little difficult to get the cover off. An interesting point to note is the cover had some rust in it, possibly from sitting for too long in a paddock?

Deciding that would be too much work we put the cover back onto the diff and went to work on removing other more interesting things. Julian began removing the remaining few intact windows. He had a process of putting a piece of small wire (from an old tire actually this time) in behind the glass from the outside and working it backwards and forwards until it heated up enough to cut through the caulking holding the glass in place. An easier way to do it is with jumper leads to a car battery so the wire is heated by electrical current rather than friction. However as we don't car about the condition of the body of the car and we didn't have any jumper leads with us we just used friction which also damaged a little of the paint.
Here Julian is trying to cut out a piece of the trim around the second window so we can get to the edge of it. In the background you can see the damage I managed to do getting the ECU out. That was the other thing that needed to get done while we were out there. So I can easily swap between the stock and custom ECU I am hoping to gut the original enclosure and use the original socket. To get the ECU out of these Falcons first you need to remove a rivet that holds the enclosure down. I didn't have a drill so I used the grinder I got for Christmas.
In my case there was also an earthing wire attached to the rivet that didn't really get much in the way of getting it out. Once the rivet is out then the enclosure will just lift off with a little jiggling and rotating.
With the enclosure out of the way the ECU just lifts out of the way allowing me to remove it from the car. Either through the week or possibly on the weekend I will start tearing down the ECU to see if I can re-use the enclosure and/or the plug and socket. For now here are some pictures showing more details of the ECU and it's plug/socket.