Topic: Transistorized ignition, points style. First ones are ready!

[Terry in Australia]

He he, busted.  Ive been thinking about going to join all the other kiwis in OZ, I hear sheep bothering is still legal over there?

John

Legal? It's bloody compulsory, ha ha! Cheers mate, Terry.

[HondaMan]

Just the one for me at the moment Mark

How much the fleet expands is currently the subject of delicate negotiations with the powers that be



PS, Once you've got a comprehensive list, I'm more than happy to act as UK distributor too if needs be.

I'll remember that, ChrisP. There's several possible units for UK.

[Terry in Australia]

Well I got home from work tonight, and lo and behold (I wonder where that expression came from?) Marks ignition module has arrived, woohoo! It's the very first one too, so I'm sure in time it will hit "Sandcast" status, and will no doubt be very collectable, ha ha!

It's a very high quality looking device, and Mark included some nice clear instructions and plenty of nice shiny new bullet connectors for me to attach to the existing wiring harness on my bike, which is a very professional touch.

Now by sheer coincidence, I busted a big old molar yesterday, (one of my own, which is unusual...........) and the jagged remains has been lacerating my tongue, so I went to the Dentist and had the remains pulled, and because I was so brave and didn't cry, (much)  Ayesha, (the very pretty Indian dentist) gave me a day off work tomorrow to recover, so guess what I'll be doing?

Yeah, it's almost (coincidentally) like I would have given my eye tooth to have a day off so I could install and test Mark's excellent ignition, ha ha! I'll be back tomorrow, with more news, and some pics too! Cheers, Terry.

[CrisPDuk]

Don't forget Terry, we will need a full photographic record of the installation. As you say this could turn out to be an historic occasion, it would be a shame for us all to miss it because you wanted to go play on your newly enhanced motorbike

[CrisPDuk]

Just the one for me at the moment Mark

How much the fleet expands is currently the subject of delicate negotiations with the powers that be



PS, Once you've got a comprehensive list, I'm more than happy to act as UK distributor too if needs be.

I'll remember that, ChrisP. There's several possible units for UK.

No problem at all. You never know, if some of them turn out to be local, they may even get the personal touch

[HondaMan]

Well I got home from work tonight, and lo and behold (I wonder where that expression came from?) Marks ignition module has arrived, woohoo! It's the very first one too, so I'm sure in time it will hit "Sandcast" status, and will no doubt be very collectable, ha ha!

It's a very high quality looking device, and Mark included some nice clear instructions and plenty of nice shiny new bullet connectors for me to attach to the existing wiring harness on my bike, which is a very professional touch.

Now by sheer coincidence, I busted a big old molar yesterday, (one of my own, which is unusual...........) and the jagged remains has been lacerating my tongue, so I went to the Dentist and had the remains pulled, and because I was so brave and didn't cry, (much)  Ayesha, (the very pretty Indian dentist) gave me a day off work tomorrow to recover, so guess what I'll be doing?

Yeah, it's almost (coincidentally) like I would have given my eye tooth to have a day off so I could install and test Mark's excellent ignition, ha ha! I'll be back tomorrow, with more news, and some pics too! Cheers, Terry.

And....as my luck has it, I just found the heat sinks I've been looking and looking for. When they arrive, I'll send on down to you to add onto the box, 'cuz it will be pretty warm, I think.

I have a pretty dentist, too. I think it's about time to go see her, too.   

[HondaMan]

Here's the BLING version cases: blue for stock coils, silver for noncosmetic type, and gold for Dyna coils. Naturally, the pretty ones will cost a little more, but for those guys who want to show it off, may be worth it. And, the gold ones are bigger to dissipate some of the Dyna coil heat better.

...AFTER testing is completed...

[Terry in Australia]

...AFTER testing is completed...

Awwww........... Couldn't I test just 1 gold one Mark??? Ha ha, Cheers, Terry.

[HondaMan]

...AFTER testing is completed...

Awwww........... Couldn't I test just 1 gold one Mark??? Ha ha, Cheers, Terry.

That's the one you'll end up with, just for helping me test it the hard way. 

[hcritz]

Purdy!!!
It's 75 and sunny here today...making it REAL hard to stay at the office!
About 4 I'm going to bail and do some riding!!!

[hcritz]

Hey Mark...
Left the office about 4:30 ...weather was awesome! Took the old girl out for a ride.
We have a nice new stretch of pavement in one of the industrial parks that has nothing on it yet and it dead ends...great place to do an Italian tune up! She ran nice and smooth all the way up to the redline...at least in the bottom three gears. Did that run a few times...so I should have nice clean plugs!  The rider had a big smile too! Sure does pull strong from about 5500 up to 8500!
 Terry....have you plugged your unit in yet??? How's the tooth???

[HondaMan]

Hey Mark...
Left the office about 4:30 ...weather was awesome! Took the old girl out for a ride.
We have a nice new stretch of pavement in one of the industrial parks that has nothing on it yet and it dead ends...great place to do an Italian tune up! She ran nice and smooth all the way up to the redline...at least in the bottom three gears. Did that run a few times...so I should have nice clean plugs!  The rider had a big smile too! Sure does pull strong from about 5500 up to 8500!
 Terry....have you plugged your unit in yet??? How's the tooth???

I broke Terry's unit, and I have to send him yours.   
I'll send yours next, after that.

[hcritz]

Morning Mark!
No problem here....she's running fine as is.
Hope Terry has his up and going!
Spending most of my spare time working on the boat right now...shooting for the end of the month for splash down!

[HondaMan]

Yeah, it seems that aluminum pop rivets and steel heat sinks don't mix well. I have fragments of aluminum floating about inside the box: I just repeated it with a 3rd unit. Gotta come up with a better assembly fastener...or something.
Of all the things...If I use a steel pop rivet, it may crack the aluminum case (done that). So, I'll have to improve the shape of the heatsink or make it from aluminum. I was trying to keep the costs down, using steel. Wasn't worth the $1.50 difference.

[HondaMan]

...AFTER testing is completed...

Awwww........... Couldn't I test just 1 gold one Mark??? Ha ha, Cheers, Terry.

Hey, Terry;
When you come back and sober up....
...I can get these boxes in anodized black, green, gold, blue and silver.
Got a preference?

[hcritz]

Hey Mark...could you drill and tap the steel heat sinks for screws???
If Looking at the picts of the unit, I'm guessing that the steel heat sink that you are talking about is the one the transistors are mounted to and the pop rivits hold that to the outer casing to transfer the heat to the case.
I'm sure getting proper hole alignment could be a pain though.
Just a thought.

[TwoTired]

Why aren't you using thread forming or thread rolling screws?

[HondaMan]

Hey Mark...could you drill and tap the steel heat sinks for screws???
If Looking at the picts of the unit, I'm guessing that the steel heat sink that you are talking about is the one the transistors are mounted to and the pop rivits hold that to the outer casing to transfer the heat to the case.
I'm sure getting proper hole alignment could be a pain though.
Just a thought.

Why aren't you using thread forming or thread rolling screws?

Ah, wish that I could, either one. There's only .030" of steel there, just enough to dampen bike vibes and hold the PC board in place. Not really enough for threads, and sheet metal screws hold poorly. And, the hole alignment, "H", is really a pain, like you said. Adding screws with nuts just adds assembly time, more cost, Loctite, all that...

For the next 2 prototypes, I'm just flipping the heatsink upside down so I can watch for the chips and remove them if they appear, plus I can remove the rivet heads after the "pop" to make sure they don't take a hike, either. The box gets warm enough that any moisture entrant will dry up in 15 minutes of run time, anyway, so that's no problem.

So, I'll have to redesign a little. If it's in aluminum, it must be .060" to damp the vibes reliably, which will start adding cost. I'll figure out something else, got 3 CAD systems to help me out. 

[HondaMan]

hondaman...i am a nubie but sounds good if you get caught up with those that already want one put me in line

thanks
john

John,
Send me your address so I can put you on this list. I'm starting a build of the ignitions.

[HondaMan]

Hey Terry...that should be a neat project! I did a couple of those conversions a LONG time ago.
The Oil filter Adaptor won't clear the engine deck lid...but you can use a remote filter without too much trouble...
But Heaven FORBID you putting an OIL COOLER on it!!!!!<G> I'd like to see some of GMs engine temp specs with and without an oil cooler...Yes...it's air cooled...but the oil is a MAJOR component in engine cooling on those.
If you buddy needs any help on the Vair motor, I may can be of some help there...

Oh...the factory oil cooler doen's have a thermostat...just like on a VW. It did have a small block off plate for Winter driving.

Hey, Mr. "H";

I've got the test unit for you ready. This unit is designed to run extra hot, so as to age the components more than normal. I', trying to get about 6 months of aging in about as many weeks, if you will be riding consistently. Please keep an estimated "ride time" log for me.

I'll PM you with the address I have: please verify it.

[HondaMan]

Hey Mark...could you drill and tap the steel heat sinks for screws???
If Looking at the picts of the unit, I'm guessing that the steel heat sink that you are talking about is the one the transistors are mounted to and the pop rivits hold that to the outer casing to transfer the heat to the case.
I'm sure getting proper hole alignment could be a pain though.
Just a thought.

Mr. H:

I sent the ignition in a box without the connectors.
The connectors are coming by envelope, might beat the box.
Oops.

[hcritz]

Hey Mark...
Sounds good...I'll be looking for it!
I'll check and see what points set I have in the bike and I'll go ahead and clean/gap/and time them before I install the box.
I'll check for the multiple fire at low rpm with the timing light as well.
Put about 150 mile on it yesterday...
When I get the box...I'll reset the odometer and keep up with miles and time.
Thanks!
HC

[HondaMan]

Hey Mark...
Sounds good...I'll be looking for it!
I'll check and see what points set I have in the bike and I'll go ahead and clean/gap/and time them before I install the box.
I'll check for the multiple fire at low rpm with the timing light as well.
Put about 150 mile on it yesterday...
When I get the box...I'll reset the odometer and keep up with miles and time.
Thanks!
HC

Mr. "H" and Terry;
I just finished the bench testing on my "control" unit and the calculations show that we need about 45 hours of test time maximum for the transistors to "burn" and change their characteristics enough to point me in the final design direction. My bench unit was run 80 hours and survived: the insides of these test units will reach over 220 degrees in a room-temperature environment, so I am hoping for more than that in hot weather, on the bike, where the engine heat is also flowing over it.

I got mine up to 280+ degees for a 4-hour run at one point: boy, does it look toasty in there now!  Everything looks good, though. I just rebiased the unit to "normal" range and it's back in test again. It runs a paltry 120 degrees now. 

Terry; did you send the first one back yet? I have the next one ready.

[Terry in Australia]

Terry; did you send the first one back yet? I have the next one ready.

G'Day Mark, yeah mate, I sent it back airmail last Monday, you should have it any day now. cheers, Terry.

[HondaMan]

Terry; did you send the first one back yet? I have the next one ready.

G'Day Mark, yeah mate, I sent it back airmail last Monday, you should have it any day now. cheers, Terry.

OK, thanks! As soon as I get to test it, I'll send out this other one. It's set up specifically for Dyna coils, and to run extra hot. These "test units" are only designed for about 200 hours of life, so as to forcibly extra-heat and age the parts inside. All in the name of research, so I can develop one I can warranty for 5 years...
I'm going out to install the very beat-up test unit I have on my bike for the Spring. It's been warm enough to melt my bike out of the ice lake it was trapped in for the last 3 months.   

Pictured below are the first 2 pre-production units. The one on the right is for use with Dyna coils (or the like), the one on the left (lacking the grommet where the wires come out) is for stock Honda, Kawasaki, etc., Denso coils. The Sharpie is there for size reference.