I did it again!

LS2 coil harness connectors with pigtails as well as everything needed to make the spark plug wires showed up today. Coils get here tomorrow. I should have ordered 2 spools of the plug wire though, since 1 only gets me enough length for 3 of the 4 needed for my planned mounting point on the side of the FM2 airbox. So I'm pondering alternate spots rather than waiting for another spool to be delivered. Currently the 3 possibilities that I'm contemplating are:

- Mounted to the firewall on the cowl side, with the wires running through the hood gap to the engine. This spot has the advantage being out of the hot engine bay and in significantly cooler air. Might cause problems with wires rubbing though.
- Mounted to the bottom of the tower strut bar. This spot would mean that any time I move the strut bar, I have to disconnect the plug wires, but has really short wires which is always a benefit.
- Mounted to a simple custom bracket on the back of the fan pack. Has the longest run of the wires that I would be able to support with what I have, but has the coils in constant airflow of roughly stable temperature.

The only custom bracket that I've seen that I could duplicate is one hanging off the exhaust side of the engine, but I'm not comfortable with them sitting right above the manifold. Lots of heat soak there.

I'm also not really willing to figure out how to mount them to the engine block, as I'd prefer to have them isolated from that vibration and direct heat transfer.

I'm leaning toward the strut bar option at the moment. Perhaps mount them to a place perpendicular to the bar, bolted to the bar, down the center of the engine. REALLY short plug wires at that point. Perhaps as short as a few inches, though long enough to have tolerance from engine shaking of course.

mike, are you going to sell your fab9 set up?
 
Maybe. An unknown still.

Not until after I've tested whatever he wants me to test, and only if he declines to take everything back and give me a refund. Considering the harness is disassembled and re-wired with quick disconnects, the plugs are well abused from all the failed start attempts,... I could see him not willing to refund me everything, and I'd have to price stuff down accordingly.

But considering how good he has been to work with, I'm hoping for that refund, or at least more than I'd get selling the kit.
 
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Well, I just fired up on LS ignition.

Of course, I forgot something, in this case I forgot to change the cyl 1/3 pins at the Hydra, so it was only sparking 2 and 4. But it says something for how strong these coils are that it fired faster with just 2 coils sparking than with all 4 on the stock setup. Fixing that oversight now...
 
All done, test drive in. Idles smoother, clearly more torque on boost roll in, engine far more responsive, ... and registering knock even at idle. With the hood open, I can heat a ping-ish sound at the same time that knock is registered. It is incredibly random, like once every 3-6 seconds, and only after the fans have just stopped running.

After pondering it a bit, I don't think it's actually knock. I mean A) the Hydra is incredibly good at saving an engine from knock once it senses it. If it's gone full ignition retard to save the engine and it's still knocking, it might not actually be knock, and B) Knocking at idle? That's retarded by itself, and C) Nothing I did would affect knock. Installed the ignition and upped the dwell to what the LS coils need.

So what I suspect is actually happening instead is that my custom hand-made plug wires (MSD parts) are arcing to the block, and at the voltage they are producing, there is excess voltage bleeding through on the knock sensor (probably a number of other sensors as well, just not picking it up at the moment). I know of at least 1 other case where an MSM was registering knock from a spark arcing problem. So the Hydra registers knock, but nothing it can do will affect it, since it's not actually knock. The sound I hear could also in theory be the arcing of the spark, rather than knock.

So I'm going to shift the plug boots a bit more to shield more of the plug, and see how that might change things. Right now they aren't far enough down to actually be around the plugs tails, and I guess they probably should be.


I guess I could start opening up my plug's gapping too now... :) Not related to the arc, but it would certainly be more power for free, and the LS coils can support it.
 
All fixed. I had the boots positioned all wrong and it was indeed arcing. So much more power on tap now that the fuel is actually being combusted and not just choked on and spit out. Amazing.

Going to open the plug gap in the morning (should be good for a bit more power now that I don't need the stock gap), and schedule some tuning, hopefully next week, though still a chance that it won't be till after LRP.
 
Yeah, definitely.

No pics of the setup intentionally. It's....messy. I'm even a bit worried about showing it at LRP. It's functional for now, but it's rather distracting in the engine bay and clearly not ideal. Trying to get a set of custom professional wires from MSD or Magnacore in before then, and if I can get that order placed, I'm going to change up how I'm mounting them, get something cleaner, more subtle.
 
Custom plug wires ordered directly from Magnacore, should get here Wednesday or Thursday, so crossing my fingers. Going to be making a bracket to mount them between the strut tower and the fender on the driver's side. Plenty of room there once I shift the cruise control module's position, and I can anchor to the fender pinch seam, firewall, and wheel well buldge. The wires will have a longer run than I wanted, but I can't find another spot I'd be happy with.
 
Nice mike! Can't wait I see all your hard work $$$$


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Magnacore wires arrived yesterday, my wife just brought me the box since apparently I hadn't noticed. Fast shipping considering that they were supposed to have been shipped yesterday from Michigan, UPS ground.

I have the tray fabricated, just need to cut out some relief holes for the coil wiring harness, paint it black, re-run the wiring, mount the coils to the tray and the tray to the car. Will be working on all of that later today and tomorrow.
 
And the LS2 coil relocation is complete...mostly :)

The tray is too flimsy for my preferences, but it is far more stable than where they were mounted, and it looks far cleaner. I.e., I'm no longer embarassed to have people see it at Lime Rock. I'll be remaking it in the near future with thicker metal. I really wish I had a welder to work with/practice with. It would make things like this so much easier.

The plug wires I got were also about 6 inches too long for some reason, so I had to route them across the firewall to "use up" the slack, rather than along the strut bar. Oh well, better too long than too short.

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very nice, yes a bit long...but it works and looks fine...and how does it run now?
 
Great to hear Mike! I'm sure you are relieved to have the car finally running properly. And way to tease Mahk. :p
 
It's just not really something that I can describe well. I mean, i can try to compare it to before on shot ignition, or to the stock turbo, or the stock turbo and factory ECU, but there is so much baseline information missing that I can't do it justice in mere text. So he will just have to take it for a test drive this weekend to see what he is missing :)

It's still not ideal, plenty of things to address.
- I still have an occasional popping from the front suspension on steering deflection + suspension compression or extension
- my battery is showing signs of weakness
- i am getting more and more cowl shake over bumps than i ever used to, so frog arms are going on my list near the top
- cold starts are giving me belt squeal from the Alt/WP belt, and I've replaced the belt twice, and it seems to keep stretching so that I can't keep tension on it, to the point that the alternator is out of tensioning distance. I probably need to grab an actual OEM belt to try.
...for the short list.

Everything else is farther out.
 
Trip home went well...no emergency stops on the shoulder were required. Hope its just a bad coil issue and dont forget to order two. ;)
 
Yeah, still missing randomly but rare while cruising as I expected. Mostly stayed out of boost, the boost was turned all the way down anyway.
 
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