A while ago in a reply to another blog post, I wrote about the current Lancer Evolution that:

“The Evo should use far improved throttle mapping where blade angle is mapped against foot position and the calculated instantaneous tractive effort value. It should also use a smaller turbo. ”

At least one reader was so excited by this notion that he wished to “quietly roll up into a foetal position and rock back and forth on the floor”. However, leaving aside bizarre responses, it’s a concept sure to interest some.

I won’t discuss the ‘smaller turbo’ bit because most of you will have a good understanding of this idea. But what about the throttle mapping?

In electronic throttle cars, the relationship between the accelerator pedal position and the throttle blade opening no longer needs to be linear. In a linear system, the throttle blade would be half open at 50 per cent accelerator pedal travel, three-quarters open at 75 per cent accelerator pedal travel, and so on.

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Look, I am sorry to say so, but I just don’t think the Lancer Evo X lives up to its hype.

In fact, as a driver’s car, I don’t think it even lives up to the (immense) promise that drives of previous Evos would lead you to expect.

There are four separate problems.

Firstly, the engine drives like an old-fashioned turbo. That is, despite the hoopla about variable valve timing, super lightweight turbo assembly and all the rest, the engine is slow to come on boost.

In fact, the engine really only gets going at just under 3000 rpm – say, 2800. Redline is 7000 rpm so that gives you just over 4000 rpm of powerband. Not terrible, but certainly nothing special.

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This week we have the first in a two-part series, one that I am very pleased with.

The series is on how to use cheap and simple electronic kits to monitor the output of the oxygen sensor.

The first story I did on this, way back in the mid 1990s, resulted in the development of the ‘Mixture Meter’ kit – thousands have since been sold.

Now we both re-introduce the narrow band sensor display, updating the story to additionally discuss what many people want from such a display (and that’s improving fuel economy) and also, in Part 2, look at how a similarly cheap and easy-to-build display can be used with wideband sensors.

The latter is especially significant: while there are plenty of aftermarket air/fuel ratio meters that use wideband sensors, we’ve never seen a description of how to tap into the standard wideband sensor fitted to many of today’s cars.

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Despite having in the past worked for an electronics hobbyist magazine, and having played with electronics for most of my life, I don’t consider myself to be any sort of electronics whiz.

In fact, I am painfully aware of how little I know and understand.

But that’s one reason I am so pleased that together with eLabtronics, we’ve been developing a whole range of off-the-shelf electronic performance modules. 

Why their need?

Well, I’ve seen it so often. Someone will ask on a discussion group or in a car club for some simple electronic device. Like, they want to automatically turn on something when a certain voltage is reached. Or they want to flash a light. Or they want a simple timer.

Always – absolutely always – there’ll be an electronics whiz that will come out of the woodwork.

Say it’s the flasher that’s desired. The ‘whiz’ will say as fast as he can:

“Oh yeah. Just use a triple-five and a few passives.”

The person making the original requests always says: “Pardon?”

Then expert says it all again, although this time faster and maybe with a URL for a circuit.

The beginner is then likely to say something like:

“OK I think I am getting it now.

“So how do I make the flash rate variable?

“And did I say, I want to pulse the car horn. Is that OK? Will the triple five do that?”

The answer of course is: no, a 555 IC won’t be able to handle the required power. And neither will it like working in a car without any protection circuitry on its power supply leads….

In fact, for every ‘simple’ circuit request, there are always – but always – complexities that are easy to overlook.

So when I say that I started working with eLabtronics over 10 months ago – and the first product is being written about in AutoSpeed only this week – you get some idea of what goes into apparently simple designs.

Of course, the eLabtronics Multi Purpose Module isn’t just a flasher. Or a voltage switch. Or a timer. The same hardware will be able to do all these functions – and plenty more – just by software changes made by the company. 

Which brings me back to the beginning. In the past we’ve covered a range of DIY modules in kit form. They were (and remain) very good designs – but the user had to build them. And many people aren’t confident or happy building electronic kits where just one, apparently trivial, wiring error can stop the whole thing from ever working.

The new eLabtronics modules are fully built and tested. Courtesy of their microcontroller design, they also have far more flexibility and options than those previous kits.

The ‘expert’ quoted above will be dismissive. But the electronics non-expert, who just wants to do all those apparently simple things, will love them….

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Here in Australia, major car modification workshops are generally well established. That’s said in the light of full knowledge that workshops come and go; but equally, others build a strong reputation and live on for decades. Some even span two or three generations of the one family.

I know that you can always find customers to denigrate any workshop, but places like Turbo Tune in Adelaide, Nizpro and Beninca Motors in Melbourne, MRT in Sydney, ChipTorque on the Gold Coast, and Romano Motors in Brisbane are longstanding workshops with good reputations.

And I wonder which Australian business – either these or others – will be first: the first to realise that there’s money to be made in specialising in a new-age of car modification.

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The (repeated) articles that we’ve recently run in AutoSpeed on power and torque are vital to understanding how to make your car go harder.

(The series can be found at Power vs Torque Part 1 -  and Power vs Torque Part 2)

And why is this understanding vital? Simply because people who use the terms ‘power’ and ‘torque’ often don’t seem to really understand what the words mean. The vital point to realise is that engine power is worked out by multiplying torque by revs.  And that’s the only way that power is worked out!

So an increase in torque at – say – 2500 rpm will mean a proportional increase in power also occurs at 2500 revs. It’s therefore just plain stupid to say “there wasn’t any change in the power curve but we got an increase in mid-range torque…” as some manufacturers of performance equipment state.

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Right now – and probably for the next few years – there’s a helluva bargain to be had.

I’ve bought one to put on the shelf and I highly recommend that anyone else into useable road performance does so too. And what should you buy? At least one of all those BA and BF Ford Falcon XR6 intercoolers that are being flogged-off on Australian eBay, commonly priced from about fifty bucks.

Yes, from fifty bucks.

Now maybe the people who want far in excess of the Falcon’s standard 240kW have an urgent need to replace these Garret-cored, bar-and-plate intercoolers with something far better, but for people who are happy to drive a car with performance not limited by wheelspin, these intercoolers look perfect. Being an all-welded design, they’d also be dead-easy to jacket with aluminium sheet, making them water/air intercooler cores. At a core size of 370 x 175 x 60mm, they’re relatively compact but have well-shaped alloy end tanks. For people wondering overall size, they’re 620 x 270 X 60 cm to the extremities. Inlet/outlet tube size is 58mm (hose ID).

Even if you consider the time and labour to fold up new end tanks from sheet aluminium and pay someone to TIG them to the original core, you’re still talking an excellent intercooler for the price.

The one I bought came with all its hoses and clamps – also very useful when you’re plumbing any intercooler into place.

Without having done any flow or temperature testing, but looking at the core and assessing the original application, I’d be happy running at least 200kW through them – more, eg 250kW – with a good water spray.

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BorgWarner Turbo & Emissions Systems has developed a new turbo speed sensor.

The eddy-current design is mounted on the compressor housing, with the end of the probe flush with the inside of the compressor cover. Designed to measure turbo rotational speeds from about 1000 rpm to 350,000 rpm, the sensor is non-contact and so wear-free.

A smart sensor that takes a 5-volt supply and includes internal electronics, the sensor body can withstand 180 degrees C and the exposed tip up to 250 degrees C. The sensor has a service life of 1.6 million kilometres.

BorgWarner suggest that a primary use of the sensor is in providing over-speed protection but the regulation of turbo speed by a feedback loop is another obvious application. As an input into the engine management system, along with temperature and ambient pressure, turbo speed measurement would allow the turbo to be run much closer to the surge line without danger. Bigger compressors and smaller turbines, allowing better low-down boost, would be the result.

Along with electric assist turbos the future of turbocharging looks bright.

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Today I returned Honda’s Type R Civic to the Queensland office. I am quite happy to see it go: I think the Civic Type R is a pretty weak car – something I make clear in our road test that will appear in AutoSpeed in due course.

With a 2 litre naturally aspirated engine that revs to 8000 rpm and develops 148kW, it might look the goods on paper – but the reality is very different.

To go further, I think the idea that small, naturally aspirated engines can compete with turbo cars is the stuff of fairytales.

The Peugeot 206 GTi 180  and Ford Focus ST170 were similar cars in concept to the Type R Honda – all based around the idea that naturally aspirated, high revving engines have some intrinsic advantage over their forced induction competitors. That’s a purported advantage over turbo competitors that have more peak power – and vastly more average power through the rev range.

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