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Do you have a Puma that is a project? Do you want to track the progress with your own thread? Feel free to do it here.

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red
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Post by red » Sat Oct 05, 2019 10:53 am

Bet you're very pleased with how that turned out!
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Wild E. Coyote
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Post by Wild E. Coyote » Sat Oct 05, 2019 6:39 pm

Cheers, Red, even more with today's achievement!

Solved the VSS problem. As you know, IB5 has VSS that sends signal to instrument cluster. The B6 gearbox from fiesta St180 has none. So had to get speed signal somehow. After deep investigation found out solution. And today succesfully tested it.

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Took out the signal of ABS sensor from Honda. Why Honda? It has single jacking point at front which enables to lift it up easily and it's ABS sensor connector is located in engine bay so easy to access.

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Puma has connectors hidden in wings, a real PIAS to get to. So highjacked the signal out of Honda. It uses same type of sensors (inductive type, sending out a sine voltage) so it is the same thing. Jacked the front end up, started her up and put in second gear to start wheels spinning to get a signal.

Now gets interesting. Opel (Vauxhall) had designed corsa C to be equipped with ABS for all versions. So no provision for VSS on that car. But when started production in Brasil, market demanded cheaper version, without ABS. So they developed operational ampifier that conditions the sine signal from ABS sensor (that corsa had ABS, i.e. wheel speed sensor on just one front wheel) and turns it to 12V square signal needed for the instrument cluster. Got myself one of this units (marketed on eBay as relays, although it is not a relay) and connected it.

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After that the signal is conditioned using the Dakota unit. Dakota itself is capable of processing the sine signal, but it needs higher input voltage (around 0,5 V AC) to detect it and therefore would speedo react only at speeds above 20 kph. The GM unit reacts sooner.
Dakota outputs 5V square signal so had to pull it up to 12V by 1 kOhm resistor.

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And after that....

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With factoring the signal by 4. The car is in my driveway, not moving at all, engine is off, yet doing 230 kph :grin:

With conditioning the signal by factor of 0,25 it si doing 30...

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Since the GM unit has very big input resistance of almost 1MOhm, splicing the signal from one ABS sensor should not affect the operation of ABS unit. Anyway, if it affects, I will just add another ABS sensor to one rear wheel and that is it. So, the speed singalling problem with B6 gearbox is solved.

A very succesful Saturday! :thumbs:
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Post by PaulZ » Sat Oct 05, 2019 7:20 pm

Bravo Wild.E, fantastic work researching and developing a solution. It must have taken a fair bit of time to find out about the Corsa in Brazil.

Keep it up :ok:
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Post by Wild E. Coyote » Sat Oct 12, 2019 4:51 pm

Today was marvelous day and just had to make use of the warm weather!

The safety belts in my car got stiff and would not wind in properly. Also, left mark on seat that proves how dirty they are (were)!

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First cleaned the seat with some microfibre cloth soaked only at one end in bucket of warm soapy water.

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And sure enough, dirt starting coming off righ away, as marking on the cloth proves.

The seat was looking better after just few rubs.

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So took the opportunitiy as the weather was so nice to clean the belts and the car as well. Got myself two buckets of warm water and put some washing detergent in one (might be Arial, not sure, got it from home laundry while the better half was away :wink: )

Took two clips (the IKEA type, soft plastic, mostly used for clamping food bags). With one secured the belt which was pulled out entirely and prevented it from gong back in.

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With saftey belt all the way out, put it in the bucket of warm water with detergent dissolved in it and let it soak for ten minutes or so...

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Now took the other clip and sqeezed it over the safety belt and started pulling the belt through.

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Dirt started coming off right away!

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Repeated 5-6 times and let it soak again for few minutes. And repeated again 5-6 times. Now took the other bucket with clean water and put it in.

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Pulled through clip but only once-twice as now there is no detergent to lubricate it and did not want to risk damaging the safety belt. The water was clear so the belt is as clean as it can get.

Used doors (exactly the right length!) to strech it for drying in the sun.

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When it was dry (left it for an hour or so in the sun and wind) took the teflon spray for lubricating. Have a can of tunap 904 which is excellent. Lubricates the belt so it goes smoothly, but doesn't make it greasy!

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And this is how the seat looks after proper drying.

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Puma also got new windscreen aerowipers as autumn is here.

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And the car in general, as it is ATM

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Post by XAF » Sun Oct 13, 2019 9:55 am

Your work always leaves me in awe Sinisa. Just amazing!!
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Post by Wild E. Coyote » Mon Nov 25, 2019 9:18 am

Hi all,

Nothing done to the car, but had a good test drive on a curvy and hilly road. The main thing is pictured here, to the right, big black thingy....

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The brakes are marvelous now. Exactly how they should be with the big disc setup (i.e. ST150 280 mm front, and Mk1 focus 253 mm at back). The pedal is firm and responsive, the effort to activate them is spot on and should you feel the need to brake harder whilst braking already, there is always enough of assistance from servo and enough of pressure in master brake cylinder which does not max out as the original one.
I am really curious how FRP brakes operate with twin piston setup at front and stock MBC? IMHO the mondeo Mk3 servo-MBC upgrade is the way to go after you have upgraded the brakes on puma.
Really, really pleased with the outcome of this operation. The car is, brakewise, ready to accept the more powerful engine :wink:
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Post by st220kyle » Sun Dec 01, 2019 1:29 pm

Nice one, I've been looking at doing this myself. Were the mk3 bolt holes for the servo the same as the pumas?
So other than the wiring for the plug and the brake lines it should be a straight swap?

I've noticed the newer MK4 master cylinder is cheaper to buy and the connections for the brake lines are in the same place as the puma's, but the reservoir will need swapping. Which could give same problems as the st150 part.
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Post by Wild E. Coyote » Sun Dec 01, 2019 4:07 pm

st220kyle wrote:
Sun Dec 01, 2019 1:29 pm
Nice one, I've been looking at doing this myself. Were the mk3 bolt holes for the servo the same as the pumas?
So other than the wiring for the plug and the brake lines it should be a straight swap?
Exactly. The servo is bolt on job really. You will find out that the pedal sits a bit lower though so some spacers will be needed or trying to get the rod from mondeo as well.
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