The Woes Of Optispark (Updated)

paulmon 14 November, 2009 20:23 Parts Permalink Trackbacks (0)

The 1994 LT1 in Brutus uses a Gen 1 "unvented" Optispark, this means it has no vent holes, meaning moisture collects and that leads to Optispark failure.  This is a well known problem, some cars go 200,000 miles with no issue while others a subject to replacement after replacement.  I believe the issues of the engine from last week's drive are just that, Optispark issues, it matches most of the symptoms:

  • Car suddenly dies and won't restart
  • Starts but immediately dies
  • Extended cranking to start
  • Rough idle
  • Sputtering
  • Backfiring
  • Trouble reaching higher rpm
  • Black smoke from exhaust
  • Poor performance with car warmed up
  • Weak plug wire spark
  • Codes 16, 36, and 42 may be set
 
More information on the above can be found at GM High-Tech Performance.
 
So I've been researching what to do about this.  Buy another $300 Opti and cross my fingers, or fix the problem once and for all.  I could change the Opti to a "Gen-II" which has better vent holes but that's not a small change, new timing set, new cam, timing cover etc etc.  It's not a 5 second thing and no guarantee.  

So replacing the Optispark with something that will stay reliable is the goal.  Here are the 4 options I've come up with: 

  1. Megasquirt with a Crank Trigger driving a Ford EDIS-8 Ignition, replaces the Optispark completely.  However the Megasquirt isn't for the faint of heart programming wise. I think I can do it but worry it will take MUCH longer than I expect. About $800cdn.
  2. Aftermarket complete Optispark unit called a Dynaspark. This is a completely redesigned Optispark that apparently solves the moisture problems of the Opti.  I'm just not fully convinced but it does come with a 12 month warranty and can be rebuilt by Dynaspark for $36.  Cost $650cdn.
  3. Delteq, this takes the high voltage out of theOptispark but would require a new Optispark since the one on the car is buggered.  Not an ideal solution but better than just replacing the Opti.  $800cdn including an "Ebay Optispark. http://www.delteq.com/
  4. Delteq+DynaSpark: Dynaspark makes the Optispark replacement designed specifically for the coil of the Delteq.  It's an Opti with just the optical signal, nothing else. Delteq+Dynaspark-III $1300

 I really want to do the Megasquirt and believe the Megasquirt is the best option, but worry about the programming.  There are many other benefits to the Megasquirt too, like data logging etc.  I've read a great deal, and this isn't a small project.  My worry here would be having trouble and not getting the car ready in time for spring not to mention never being happy with the tune and always fiddling with it.  This isn't just an ignition change but a complete change to the car's computer, that means wiring changes, etc.  I'm sure I can figure it out, I just worry if I can do it quickly enough and will be happy with the final product. 

If you have any other ideas, or have tried any of the above combinations I'd love to here about them in the comments below.  Likewise if you know about a shop in the Toronto area that knows Megasquirt well, let me know.

Update: Two other options have been discovered:

1) LTCC, similar to the Delteq system except 8 LSx coils.  Cost ~$650 including LSx coil packs. http://www.bailey-eng.com/LTCC.html

2) EFI Connection 24x kit with the required parts to swap out the LT1 ECM for the LS1 PCM.  Kit includes cam reluctor new timing cover, crank reluctor, and requires a harness modification and new LSx computer.  Cost for the "kit" is $525 and requires a harness ($650 or DIY $100) and LS1 PCM ($100) + LS1 coils (~$250 OEM).  This sounds like a happy medium between Megasquirt and Delteq/LTCC.  Assuming I can figure out the harness. http://www.eficonnection.com/24x/

This means I have 6 options. I like the idea of the EFI Connection 24x but again worry if I will run into problems, if that is going too far...Current thinking is either the LTCC options, the Dynaspark alone or the EFI Connection... 

Some Driving....

paulmon 09 November, 2009 23:22 General Permalink Trackbacks (0)

The engine is in and running, but it's not happy.  I suspect a sensor, but more than likely the curse of the original Optispark is what's hit me.  The orginal Optispark hated moisture since it didn't have a vent hole to drain any collected moisture.  Electricity and moisture don't mix.  So something to work on this winter, with any luck I'll be flying by spring. :)
 
Here's a 30 second clip of the drive. 
 
 

Engine Installed

paulmon 15 August, 2009 12:13 General Permalink Trackbacks (0)

The engine has been reinstalled - Just need to order the flow through water pump from Stewart to wake the beast.
 
Rebuilt engine mostly installed. 

Engine Rebuilt: Finally Some Progress!

paulmon 10 August, 2009 12:55 Parts Permalink Trackbacks (0)

The engine is back from Wright's Engine Service.  Looks good.  Finished spec, 355 with forged pistons, new rods, street port of heads.  Can't wait to get the car running, only about 6-8 weeks of good weather left.  Granted this summer "good" is a relative term.
 
Here's before and after of the engine.
 
Rebuilt LT1 Exhaust Header
 
Also going to add an electric water pump to simplify the cooling system, LT1 cooling can be problematic.

More to come in a couple weeks. 

Twitter @Paulmon

paulmon 14 May, 2009 17:43 General Permalink Trackbacks (0)

Little updates are going to be on twitter, too much on the go for longer blog posts.  Check me out and follow me twitter name paulmon, word of warning, I talk about many different things from the car to my day job IT gig, wine and food, so it isn't just locost stuff.

Engine And Other Misc Updates

paulmon 14 May, 2009 17:30 General Permalink Trackbacks (0)

Mid-May, the engine is still at the builder, unfortunately not a ton of progress on that front.  I did get all the parts for the rebuilt and it is expected that he will start on the engine in about 3 weeks.  It's cleaned and disasembled, just needs to be bored, honed and reassembled.  Keeping the stock crank shaft, going for a street port, angled valve job and switching the rods (stretched) and pistons to forged.  Typical bottom end rebuilt.  Sticking with the stock cam shaft too, since it's pretty much pancake flat and I don't want to change the power band until I'm sure everything else on the car is the way I need it.
 
Piston:
 
Forged Piston
 
I'm going to be ordering a new steering pinion for the Woodward rack I'm using.  FrankenMini wasn't a street car, so the lightening quick rack, 2.62" per turn, wasn't too hard to handle.  Brutus is a completely different beast and it only took one slow drive down the road to see the rack was "white knuckle" quick.  Dropping it down to a 2.09" per turn which is still ripping fast, but considerably slower than what I have now.  Benefit of these Woodward racks is I can quickly change out the ratio with simple hand tools. 
 
Another update coming when the engine is done. :) 

More Engine Pictures

paulmon 08 April, 2009 18:28 General Permalink Trackbacks (0)

The engine isn't that bad.  Pretty much what I suspected, blown head gasget, so just a "standard" rebuild is needed.  As mentioned in a previous post I'm going to focus on the bottom end and strive for reliability rather than power.  I'm still on the fence with hyperurtectic or forged pistons, mostly due to cost.   I need new rods, they looked like they were stretched, but aside from that everything else seems to be fine.  Some pictures below, notice the snapped ring (near the reflection) on the piston.
 
Broken Ring
 
Notice the blow by between pistons, sign of a blown head gasket.
 
Crank. 
 
 
 

Movement

paulmon 22 March, 2009 23:12 General Permalink Trackbacks (0)
Not many updates since the discovery of the engine's condition, that's about to change. Dropped the engine off today at Wright Engines to start the rebuild. Bill Wright was kind enough to meet me on a weekend which was nice and convenient. Current thinking, but this may change due to budget: Bore 30 over (355) Good set of rings and Hypereutectic pistons Balance the bottom end Port & Polish the heads Cam Shaft (raise the power band very slightly) From what I've been reading, and some good advice from the boys over at www.ls1lt1.com and LT1 with these mods is good for around ~400hp, which in my 1600lbs car is bordering on lunacy. But it's fun! :) More to come when I hear back from Bill on the engine.

Engine Woes

paulmon 17 December, 2008 18:31 Parts Permalink Trackbacks (0)

At the end of the season the car was blowing off the rad hose on a cold engine; suspecting it to be the head gasket the heads were finally pulled the other day.  Not good. Cry
 
The block is suspected to be cracked in two places and the heads are warped.  Serves me right for not pulling the heads day one.  At least there is plenty of time before good weather is upon us to sort out what to do about this.  Not sure how fixable the block is, should be able to machine the heads.  Depending on cost this sounds like a good time to do some clean up in the engine, replace the pistons, valves, springs, etc, budget might not allow that though.
 
*sigh* no one said this was going to be cheap, but I was also not looking for a pit full of fire to "store" my money either.
 

  

Completed Car

paulmon 13 October, 2008 17:40 Parts Permalink Trackbacks (0)

 

Haven't posted these pictures yet, so here they are.  Car is effectively complete minus some paint and some tweaks to things like the air intake.

 

Effectively the completed car.

Effectively the completed car.


Registration Process Or How To Pull Your Hair Out

paulmon 26 September, 2008 16:37 General Permalink Trackbacks (0)

Ontario LogoWent to the MTO today with everything I needed to get my VIN.  The first step in getting my car legal for the road.  This isn't going to be as easy as I had hoped.

Everything I've done is based on this:  http://www.canadianrodder.com/features/fyi/registering.htm

Today started off with a trip to the lawyer to get my Affidavit/Declaration done.  This was pretty painless.  Wrote everything up, I signed it, they stamped it. Done.

I then directly to the MTO (Square One location in Mississauga) to get my VIN.  First issue.  The person helping me has never done this but he knows it can be done, just not sure how.  Other person in the office said she hasn't had anyone in 3 years ask her to register a "Kit Car" and she can't remember what the process is.  Fan-freaking-tastic.

They call Kingston, where MTO main office is, they talk for a while and agree to fax over everything I've brought in so Kingston can look at it.  I have a seat and wait for 30 minutes while they do this.  They come back asking for a Declaration of Origin on my engine.  Not something, according to the URL above, that I need.  They don't know where I can get such a declaration, they simply want it.  Considering I bought the '94 Camaro engine from a scrap yard that thought it was a '96, I don't think the scrap yard will be any help whatsoever.  They seem to think the engine is new, even though I keep telling them it is used and from a scrap yard in Michigan.  Cry

I talked to them a little longer trying to explain that the engine is used, and I don't believe I need such a declaration.  All I get is a "Kingston said" response.  After talking to the more senior official at the local office it was agreed they would take copies of my paper work, and look into it and call me.  It's currently 6pm and they haven't called me. Frown

That's where things sit now.  I'm sure that if I had an MTO official that has dealt with kit cars before, I wouldn't have to go through this bureaucratic hell, but that's where I am.  If anyone knows of someone at the MTO with more experience in such things I'd love a contact name and number.

Argh.  This is going to take much longer than I imagined.  *sigh*

First Drive!!! OMFG This Car Is Fast!

paulmon 13 September, 2008 16:45 General Permalink Trackbacks (0)

Drove the car today for the very first time.  OMFG this car is FAAASSSSTTT,  warp speed fast!  Final weight is 1650lbs, add a 300hp engine and so much torque that you can pull away from a stop in 4th gear and you've got a car that can bend space & time.  One thing does need to be changed, the steering rack is just way too quick.  The rack is out of FrankenMini which was designed for autocross where a quick rack helps.  However this rack in Brutus is too quick for the street, quite a "white knuckle" experience.  Thankfully I can change the pinion in this rack and slow it down.
 
You'll notice rain on the camera lense during the video.  Unfortunately that's not rain but water from the cooling system, car sprung a small leak. 
 
With no further delay, here's the video:
 
 

Emergency Brakes And Other Fine Stuff

paulmon 05 September, 2008 19:06 General Permalink Trackbacks (0)

Lokar Midnight SeriesLokar's "Midnight Series" floor mount emergency brake handle, the last thing needed on the "let's get this street legal list."  Also ordered the cable set and the boot.  Got this locally at Horton HotRod Parts. First time dealing with them and so far they're great.  Cost was similar to ordering from the US when you take into account shipping etc.  Will deal with them again.

 Finally I've started to think about how to cover some of the interior aluminum.  I think I'm going to get either a carbon fiber or leather looking pleather vinyl to apply to the trans tunnel and dash.  At a minimum.  Might consider a little more but I doubt it.

Still need to find somewhere that I can get this sucker weighed up near Meaford. *sigh* 


Nose Cone Grill

paulmon 01 September, 2008 11:39 General Permalink Trackbacks (0)

 

I posted about this a few months ago now.  Various ideas for a grill floating around in my head, then I saw the picture below.

My grill is now done, and this is what it looks like, something still needs to be figured out for the air intake.

 


We Have Life! The Engine Starts!

paulmon 24 August, 2008 17:33 General Permalink Trackbacks (0)

Starts with no problems at all. :) 11 Months to get to this point. 

What remains to get the beast mobile:

  • VIN From MOT
  • Emergency Brake Handle and Cable
  • Tires that will pass saftey
  • Saftey
  • Insurance
That's about it to get it rolling on the street.  Much more work to be done to get the beast looking good, starting with a hood scoop for the big air intake.
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