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  1. casuprock

    HE351VE Controller Project

    Hey folks, I just wanted to let everyone know that we are done with development on this project and it's become a real product. Thank you for all the feedback and support during the process. The project started as a hobby endeavor and has become much more. The final specifications are listed at...
  2. casuprock

    VGT - Blaylock Switchblade

    Sure. Here's a pair of the 10-10 runs with engine RPM on the X axis. The dyno folks printed these with time on the graph too hah. I will get a better printout with both runs on the same axis. The torque and power curves are clear though. the other thing to look at is the min/max/avg torque and...
  3. casuprock

    VGT - Blaylock Switchblade

    This is an S300 frame turbo with a 63mm compressor and 0.86AR turbine housing. The open housing runs are equivalent to a stock S300, so that is the baseline- the vane is retracted entirely out of the flow. You can refer to the performance of an S300 63mm on a 5.9L, typically they're laggy with...
  4. casuprock

    HE351VE Controller Project

    Yeah it is the dates of the runs.
  5. casuprock

    HE351VE Controller Project

    Back to the dyno! The improvement and optimization continues. Here is an overlay of the dyno run from last week and another from this week's test:At this point, we've gone from 500 ft*lb at around 5 seconds to 500 ft*lb at around 1.5 seconds ON THE SAME TURBO by means of proper VGT...
  6. casuprock

    VGT - Blaylock Switchblade

    Back to the dyno! The improvement and optimization continues. Here is an overlay of the dyno run from last week and another from this week's test:At this point, we've gone from 500 ft*lb at around 5 seconds to 500 ft*lb at around 1.5 seconds ON THE SAME TURBO by means of proper VGT...
  7. casuprock

    VGT - Blaylock Switchblade

    Lots of design and development happened. Major results. Turbo was a Blaylock Switchblade. Test was conducted on a Cummins 5.9L (DSM will follow).Dyno compares the vane control versus open housing (no vane).This is what the boost looks like with vane control active and not active. This...
  8. casuprock

    HE351VE Controller Project

    Lots of design and development happened. Major results. Turbo was a Blaylock Switchblade. Test was conducted on a Cummins 5.9L (DSM will follow).This dyno run compares the vane control versus open housing (no vane).This is what the boost looks like with vane control active and not...
  9. casuprock

    VGT - Blaylock Switchblade

    Vane increasing turbo speed at idle: Switchblade II vane control increasing turbo idle speed - YouTubeVane building boost at 60mph cruise on level surface: Switchblade II building boost on level highway cruise - YouTube
  10. casuprock

    VGT - Blaylock Switchblade

    As Kevin Thackston always points out, the rotating mass is everything. The effect of the variable vane is amplified by having a small inertia. Torque on the turbine wheel equals inertia * angular acceleration. Our job is to increase the torque the flow exerts on the wheel at low speeds. We are...
  11. casuprock

    VGT - Blaylock Switchblade

    Hey gents, it has been a while. Haven't been religious about updating partly because my wife and I had a baby and he's been a more important project than this the last few months. :thumb:We did test the Switchblade on a DSM and determined that the design of the vane derived for diesel...
  12. casuprock

    VGT - Blaylock Switchblade

    It is a lot bigger than the HX40.
  13. casuprock

    VGT - Blaylock Switchblade

    :ninja: Soon you'll wake up to find all of the results have been posted silently in the middle of the night, just like a ninja visit. :DHere is an interesting comparison of exhaust housing sizes between the Switchblade and other turbos.Aurora 5000 on the right, Switchblade on left...
  14. casuprock

    VGT - Blaylock Switchblade

    The vane was opening prematurely for the maiden voyage due to a poor choice of sensor location in the compressor housing :coy:I think this is great since the next steps are to tune the engine better, probably get bigger injectors, and relocating the sensor in the housing. It's a beast right...
  15. casuprock

    HE351VE Controller Project

    http://www.dsmtuners.com/forums/turbo-system-tech/457852-vgt-blaylock-switchblade.html#post153245279
  16. casuprock

    VGT - Blaylock Switchblade

    This thing is a monster. OMG Outran 950cc injectors with ease. Building boost by 4k. We're addressing some minor sensor issues and Thaxton Design is planning on getting 2000cc injectors put in this test vehicle before we continue with tuning or hit the dyno.Variable vane turbocharger on 2G...
  17. casuprock

    VGT - Blaylock Switchblade

    The switchblade has a 19cm exhaust housing, the EGTs won't get that high because the back pressure can be controlled by the vane to stay equal to or less than the charge pressure. That's one of the reasons it is an intriguing design. Its simplicity is also to its benefit in surviving high...
  18. casuprock

    VGT - Blaylock Switchblade

    The Switchblade has a T4 flange.We're going as fast as we can! :p
  19. casuprock

    Variable Vane Top Mount Build 97 GSX

    Yup... a 63mm compressor wheel accelerates (spools) like it's a 16g... Video from Blaylock Turbos. :hellyeah: Blaylock Switchblade Turbo Accleration with Suprock Technologies VGT Controller - YouTube
  20. casuprock

    VGT - Blaylock Switchblade

    A 63mm compressor wheel accelerates (spools) like it's a 16g... Video from Blaylock Turbos. Blaylock Switchblade Turbo Accleration with Suprock Technologies VGT Controller - YouTubeThe compressor wheel in the videos is a Borg Warner 63mm in Blaylock's compressor housing. They also do a...
  21. casuprock

    HE351VE Controller Project

    A 63mm compressor wheel accelerates (spools) like it's a 16g... Video from Blaylock Turbos. Blaylock Switchblade Turbo Accleration with Suprock Technologies VGT Controller - YouTube
  22. casuprock

    Trying to reach the dsm turbo gods (turbo related question)

    Contact Jim Blaylock at Blaylock Turbo. He is making small VGT turbos for custom motorcycles. He's on this site, PM jimblayhttp://www.dsmtuners.com/forums/turbo-system-tech/457852-vgt-blaylock-switchblade.html#post153205948
  23. casuprock

    Turbo setups

    up to speed quickly with big flow- http://www.dsmtuners.com/forums/turbo-system-tech/457852-vgt-blaylock-switchblade.html#post153205948
  24. casuprock

    HE351VE Controller Project

    The controller can also display warnings on the gauge pod when the connected sensors exceed their user specified limits. While the warnings are valid if a value is exceeded, everybody can appreciate the reference to fast and furious. LOL<iframe width="560" height="315"...
  25. casuprock

    VGT - Blaylock Switchblade

    We'll see what we can do with this turbo on a DSM fairly soon. I have high expectations for this turbo. Much better than the valve types. Blaylock has a good idea here. :thumb:
  26. casuprock

    HE351VE Controller Project

    PC configuration software allows the user to choose which type of turbo (i.e. HE351VE, Switchblade, etc. corresponding to the default vane control settings). It also allows advanced control over the turbo vane position settings if the user wishes to deviate from the standard position control...
  27. casuprock

    faster spooling turbo?

    http://www.dsmtuners.com/forums/turbo-system-tech/457852-vgt-blaylock-switchblade.html
  28. casuprock

    HE351VE Controller Project

    Branch to other thread about the VGT controller on the Blaylock Switchblade turbochargers: http://www.dsmtuners.com/forums/turbo-system-tech/457852-vgt-blaylock-switchblade.html#post153205948This thread will remain about the controller development to prevent confusion.
  29. casuprock

    VGT - Blaylock Switchblade

    This thread is about the Blaylock Switchblade turbocharger and its control actuation. The Switchblade is a variable aspect ratio turbo that uses a single aerofoil type vane to direct the flow of exhaust gas around the exducer wheel. I think the Switchblade is an interesting design because of its...
  30. casuprock

    HE351VE Controller Project

    It requires no inputs from the ECU.
  31. casuprock

    HE351VE Controller Project

    The HE's will last but the mechanical assembly is fussy without proper cooling. The HE design was (in my opinion) more about diesel EGR than it ever was about variable vane performance... the reduced lag is a desirable side effect of the HE design that we're taking advantage of.We are...
  32. casuprock

    HE351VE Controller Project

    Feedback control demo from sensor inputs: Blaylock Switchblade on Suprock Technologies VGT Controller. Position Control. - YouTubeEngine brake and resume from engine brake: Blaylock Switchblade on Suprock Technologies VGT Controller. Engine Brake. - YouTube
  33. casuprock

    HE351VE Controller Project

    What's this? A new VGT that can crush spoons?http://www.youtube.com/watch?v=I6RbVov1hB8It can crush spoons, but can it crush records? :sneaky:Here's a shot of our EGT probe. It's all custom made. The sheath is 310 stainless, exposed tip type K thermocouple. The bung is custom machined...
  34. casuprock

    HE351VE Controller Project

    Testing ought to tell us how well it does. It's about time I get some install and test video to show everyone. When I do, I'll upload the data logs as well.The first videos may very well show a turbo making north of 50lb boost.Getting very close. ;)This may sound picky, but can we call...
  35. casuprock

    HE351VE Controller Project

    Graphics animations on the gauge pod: Pre-Release Variable Geometry Turbocharger Controller- Gauge Pod Animations - YouTube
  36. casuprock

    HE351VE Controller Project

    Our controller automatically zeros the vane position on startup. There is no need to calibrate. We use a position controller and stepper motor unlike the Cummins Holset actuator that uses a magnetic position indicator on one of the gears in their gearbox.The CHRA of this turbo requires...
  37. casuprock

    HE351VE Controller Project

    The probes go pre and post turbo. You don't have to modify the housings or anything.
  38. casuprock

    HE351VE Controller Project

    Here is a major update. The next update will show the final gauge pod display graphics. Thereafter, expect installation videos in a DSM.Thanks for everyone's continued interest in this thread! We're moving a mountain with this project and doing it right takes time (because we don't have...
  39. casuprock

    Exeter NH Meetup

    Starting a meetup for people in near the NH Seacoast area. Sept. 21 @ 6:00 PM. See meetup link below to RSVP.I am working on a number of performance products and I am interested in starting a network of people in the area for testing and development. With our proximity to New England...
  40. casuprock

    NH DSM friendly repair shop

    Here's a solution to your problem. http://www.dsmtuners.com/forums/tuning-engine-management/394945-force-obd-inspection-pass-2g.html
  41. casuprock

    HE351VE Controller Project

    Here is a very interesting plot of pressure during two pulls. Since we are sampling so fast and have uber resolution, we can see frequency components in the pressure as outlet pressure fluctuates with engine breathing. This kind of plot is called a spectrogram and shows the frequency content of...
  42. casuprock

    Coil Commander- 16.2V Ignition Voltage Boost

    Cool. What kind of logging can you do to test this out? Can you capture info about knock, timing, etc.? I am hoping to see solid data to compare stock voltage versus 16.2V on different setups. PM me and we can talk more.
  43. casuprock

    Coil Commander- 16.2V Ignition Voltage Boost

    Yeah sure, what kind of current do they draw?I own a CDI system and still made this because there are a bunch of possible uses plus people who don't like CDI or swear by the stock coils will like this device.
  44. casuprock

    Coil Commander- 16.2V Ignition Voltage Boost

    Yeah that's why I'm running at 16.2 instead of 24V, the transistors can take that with no problem since they'll be specified for much higher than their expected operating range. 24V might be pushing it with the stock transistor pack.If this 16.2v works out, I'll look into making an upgrade...
  45. casuprock

    Coil Commander- 16.2V Ignition Voltage Boost

    I'm working on a new project, the Coil Commander, a 16V converter to run stock ignition coils at 16.2V instead of the stock 12-14V system. The stock coils are pretty darn good parts and it would be nice to supply them better. There are 16V batteries available, but the rest of the car and ECU...
  46. casuprock

    HE351VE Controller Project

    One thing to do would be to use a ceramic capacitor between the leads of the thermocouple to reduce noise with the Maxim part. Keep in mind this will increase your time constant (slower response) but could help if you encounter noise issues with higher sampling rates. Noise increases with faster...
  47. casuprock

    HE351VE Controller Project

    Be careful before jumping into TCs. There's a reason it took months to develop a good sensor and interface (and it's what I do for a living). Thermocouples are more involved than thermistors to get good noise performance because the voltages are much lower. They have to be designed properly to...
  48. casuprock

    HE351VE Controller Project

    I have a few questions for everyone following this thread: 1. Who wants to see a second pressure sensor for measuring exhaust backpressure with similar resolution and speed to the charge pressure we are already testing? 2. Who wants to see a second thermocouple input for measuring exhaust...
  49. casuprock

    HE351VE Controller Project

    Thank you for the encouragement!
  50. casuprock

    HE351VE Controller Project

    "Adiabatic... now there's a word I've not heard in a long time."Hey, guess what... We adjusted the PGA gains before the ADC on the hardware and voila, 10x better noise performance! It helps when you take advantage of the hardware built into your design. :rolleyes: I'll get some new data...
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