It isn’t often we get a project that has an eighteen-year-long timeline, as staying focused on one project for that long is a significant investment of someone’s lifetime. But when you’re making your own carbon copy Mclaren, you need to be prepared for it to take a while. Unfortunately, there are only 6 of them in the world so for most people if you want one, you need to make your own.
Granted, in those eighteen years, [Brough Built] freely admits there were some gaps. He scrapped most of the earlier work, and today’s current iteration took about three years. This car is made of steel, aluminum, foam, carbon fiber, and sweat. It is a close copy of the F1, and it has all the features you would expect to see on the real thing, like the centered driver’s seat and the gold cladding in the engine bay.
A BMW V12 engine mated to an Audi six-speed gearbox provides the power inside the car. A custom clutch assembly was machined to make it all work. Overall, this is an incredible build with time, and precision just poured into it. Folding and cutting all that metal alone, not to mention all the meticulous welds on everything from the gas tank to the door panels.
Making your own car is a complex and long journey that can be incredibly rewarding. Perhaps not a copy of an existing vehicle but something new; check out this soap shaped hand-made electric car.
When he’s not busy with his day job as professor of computer and automotive engineering at Weber State University, [John Kelly] is a prolific producer of educational videos. We found his video tracing out the 22+ meters of high voltage cabling in a Tesla Model S (below the break) quite interesting. [John] does warn that his videos are highly detailed and may not be for everyone:
This is not the Disney Channel. If you are looking to be entertained, this is not the channel for you.
We ignored the warning and jumped right in. The “high” voltages in the case of an electric vehicle (EV) like the Model S is approximately 400 volts. Briefly, external input via the charge connector can be single or three phase, 120 or 250 VAC, depending on your region and charging station. This get boosted to a nominal 400 VDC bus that is distributed around the various vehicle systems, including the motors and the battery pack.
Rear Modules
Charge receptacle
On-board charger module
Rapid splitter
Rear motor inverter
Front Modules
High voltage junction block
Cabin air heater
DC to DC converter
Battery coolant heater
Air conditioning compressor
Front motor inverter
He goes through each module, showing in detail the power routing and functionality, eventually assembling the whole system spanning two work benches. We liked his dive into the computer-controlled fuse that recently replaced the standard style one, and were impressed with his thorough use of labels.
If you’ve ever been curious about the high voltage distribution of a EV, grab some popcorn and check out this video. Glancing through his dozens of playlists, [John]’s channel would be a good place to visit if you’re interested any topic related to hybrids and electric vehicles, drive trains, and/or transmissions. We’ve written about some Tesla teardowns before, the Model 3 and the Model S battery packs. Have you worked on / hacked the high voltage system in your EV? Let us know in the comments below.
Nice thermal design, but conformal coating and no ID marks make this tough to reverse engineer
[Willem Melching] owns a 2010 Volkswagen Golf – a very common vehicle in Europe – and noticed that whilst the electronic steering rack supports the usual Lane Keep Assist (LKAS) system, and would be theoretically capable of operating in a far more advanced configuration using openpilot, there were some shortcomings in VW’s implementation which means that it would not function for long enough to make it viable. Being very interested in and clearly extremely capable at reverse engineering car ECUs and hacking them into submission, [Willem] set about documenting his journey to unlocking openpilot support for his own vehicle.
And what a journey it was! The four-part blog series is beautifully written, showing every gory detail and all tools used along the way. The first part shows the Electronic Power Steering (EPS) ECU from a 2010 Volkswagen Golf Mk6 module (which rides on the back of the three-phase steering rack motor) being cracked open to reveal an interesting multi-chip module approach, with bare die directly bonded to a pair of substrate PCBs, that are in turn, bonded to the back of the motor casing, presumably for heat dissipation reasons. Clever design, but frustrating at the same time as this makes part identification somewhat tricker!
Entropy less the 1.0, and zero sections indicate no encryption applied
[Willem] uses a variety of tools and tricks to power up and sniff the ECU traffic on the CAN bus, when hooked up to a SAE J2534-compliant debug tool, eventually determining it speaks the VW-specific TP2.0 CAN bus protocol, and managed to grab enough traffic to check that it was possible to use the standard KWP2000 diagnostic protocol to access some interesting data. Next was a very deep dive into reverse engineering update images found online, by first making some trivial XOR operations, then looking at an entropy plot of the file using Binwalk to determine if he really did have code, and if it was encrypted or not, After running cpu_rec, it was determined the CPU was a Renesas V850. Then the real work started – loading the image into Ghidra to start making some guesses of the architecture of the code, to work out what needed patching to make the desired changes. In the final part of the series, [Willem] extracts and uses the bootloader procedure to partially patch the code configuration area of his vehicle and unlocks the goal he was aiming at – remote control of his steering. (OK, the real goal was running openpilot.)
In our opinion, this is a very interesting, if long, read showing a fascinating subject expertly executed. But we do want to stress, that the vehicular EPS module is an ASIL-D safety tested device, so any hacks you do to a road-going vehicle will most definitely void your insurance (not to mention your warranty) if discovered in the event of a claim.
When looking at the performance of a vehicle, weight is one of the most important factors in the equation. Heavier vehicles take more energy to accelerate and are harder to stop. They’re also more difficult to control through the corners. Overall, anything that makes a vehicle heavier typically comes with a load of drawbacks to both performance and efficiency. You want your racecar as light as possible.
However, now and then, automakers have found reason to intentionally add large weights to vehicles. We’ll look at a couple of key examples, and discuss why this strange design decision can sometimes be just what the engineers ordered.
When modern connected cars cross continents, novel compatibility problems crop up. [Oleg Kutkov], being an experienced engineer, didn’t fret when an USA-tailored LTE modem worked poorly on his Tesla fresh off its USA-Europe import journey, and walks us through his journey of replacing the modem with another Tesla modem module that’s compatible with European LTE bands.
[Oleg]’s post goes through different parts on the board and shows you how they’re needed in the bigger picture of the Tesla’s Media Computer Unit (MCU), even removing the LTE modem’s shield to describe the ICs underneath it, iFixit teardown diagram style! A notable highlight would be an SIM-on-chip, essentially, a SIM card in an oh-so-popular DFN package, and thankfully, replacing it with a socket for a regular SIM card on some extender wires has proven fruitful. The resulting Tesla can now enjoy Internet connectivity at speeds beyond those provided by EDGE. The write-up should be a great guide for others Tesla owners facing the same problem, but it also helps us make electric cars be less alike black boxes in our collective awareness.
Every few years, someone pushing a startup to investors comes up with an acronym or buzzword which rapidly becomes the new hotness in those circles. One of the most pernicious is “as a Service,” which takes regular things and finds a way to charge you a regular fee to use them.
Automotive companies just absolutely loved the sound of this, and the industry is rapidly moving to implement subscription services across the board. Even if there’s hardware in your car for a given feature, you might find you now need to pay a monthly fee to use it. Let’s explore how this came about, and talk about which cars are affected. You might be surprised to find yours already on the list. Continue reading “New Cars Will Nickel-and-Dime You – It’s Automotive As A Service”→
Bluster around the advent of self-driving cars has become a constant in the automotive world in recent years. Much is promised by all comers, but real-world results – and customer-ready technologies – remain scarce on the street.
Today, we’ll dive in and take a look at the current state of play. What makes a self-driving car, how close are the main players, and what can we expect to come around the corner?
