Carbon Fibre Emotion Control Unit

[mb1]

macpaul said:

Second that.

MB1, do you have all the contact details of those who are interested, Volvo and ECU, for when the thread is deleted?

I trust PH understood that all we are doing here is grouping together to make a limited run of special keys for our cars. And I am pleased to see the thread is still running without problems.

Yes, I have all details.
So far 19 firm orders for the ECU out of 35 members who raised interest.
24 interest recorded for the Volvo fob.
I will wait for the first prototypes of the ECU before starting anything on the Volvo (except CAD geometry).

Everyone on the ECU list should have been contacted privately now. If you have not been, just PM me.
I will contact the Volvo list as soon as I am ready to launch tools.

Mb1

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Tooling is being made up for the ECU as we speak - I will be posting pictures as soon as i have something worth sharing.

A UK dealer is sending me this week a Volvo fob so i can create the CAD models.

I will then wait to see the quality of the ECU parts before launching the Volvo fobs.

Just a bit more patience ;-)

Mb1

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WantanewV12V said:

I am interested in a CF ECU for my V12V - am I too late for the first run at £150 ?

No, you are not too late. Still going through the mould machining. Trying to get a first prototype in time for the Hever get together next week but it will be very tight.

I will email you later today.

Thanks.

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Hi All,

A short update on the carbon fibre ECU and Volvo fob projects.

+ ECU:
Due to the parts being small and all the good machine shops full with large automotive and motorsport projects, it has proved difficult to get a slot.
I did not want to go with a supplier I did not know so I had to wait for my preferred supplier to give me a slot. They had issues with their 5-axis machine resulting in 3 weeks delay on all projects...

The good news is that they finally started to cut the patterns this week. So getting closer to tools being ready and the first prototype.
More progress and pictures as we get nearer to prototype.

+ Volvo fob:
I have received one of those from a dealer this week and will start CAD work this week.

Thank you all for your patience...

1 of the ECU Patterns:

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I should get the first 2 prototypes of the ECU shortly.

I do not think range will be affected. The carbon layer is very thin. Also the glass key has a lot of metal in it and it seems fine.
But I will be able to test shortly and post pictures of the actual parts (there are pictures of the CAD on this thread if you go back to the start).

Mb1

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notsaV8V said:

Mike,

How's the project going?

Thanks for asking !

Not as fast as I would like...

I decided to go with a company that can make quality components but because it is a small project and they have a lot of work at the moment (plus it is the holiday season), it is not progressing very quickly.

They finished the moulds a couple of weeks ago. They are doing the first prototypes now. There is one part (the top cap) which is causing them some issues and they are working their way around it.

I am still planning to do the volvo fob, but only when the ECU is sorted and shipped to the people who kindly supported the project.

I will post pictures of prototypes as soon as I have them in hand.

[mb1]

A quick update. Getting there slowly...

They finally did a few parts this week. Good result on the body of the ECU as you can see in the attached picture.
However, the cap is still not good enough.
So, we will redo one of the mould to include the cap, which will work a lot better and remove all the little details that are actually not needed on the CFRP version.

I will send more news as soon as the new mould is ready.

[mb1]

Hello everyone !

Sorry, I missed the earlier posts from this week. It is only because I started receiving emails about the topic that I realised some were interested in the progress of the CFRP ECUs...

Well, the Carbon Fibre ECU has been a long journey ! Tiny carbon fibre parts are never as easy as they might look. And after multiple delays in selecting the right supplier, waiting for machining slot, changing the concept of the case due to a wrong split line and then getting the right quality from the supplier, "engineering" new buttons and how to hold the circuitry... Finally, I managed to get the first 15 ECUs fully complete this weekend, and the first 15 buyers will get their keys next week.

Some pictures:




I would like to thank all of the first buyers, who have supported the project since the very beginning. They have shown incredible patience.
The ECU is still a self-made kit, and I am sure there will be a few niggle along the way, but there must be a reason why it is the first time it has ever been made !
Thanks Pistonheads and its members !

I have made batch orders of 15 cases. I receive the bear carbon cases and then I have to mould the internals to hold the circuitry just right...
I also had to make new buttons as I could not use the original ones.

The next batch of bear cases will get to me sometime next week, and it takes me about 2 weeks to get them done.
I have a handfull of cases not sold as part of the second batch. If you want one, just get in touch via pistonheads or [e-mail]

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bananarob said:

Still interested although guess I need to wait until my car arrives?

It might be too late ;-)

Only 3 left from the second batch of 15 and not sure if I will get enough on top to warrant another batch of 15, so there might only be 30 ever made ;-)

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IanV12VR said:

Best to send Michael a PM - I think he is too busy making our ECU's to check PH very often

Indeed !

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v8woollie said:

Oh please make something like that to repalce the Volvo fob. The same but with cutouts for the Volvo fob buttons would be ideal

It was the plan since the beginning. I have received a volvo key fob to create the necessary tools but I have not even had the time to look at it.
The CFRP ECU is quite complex on my side to create the moulding to hold the circuitry... I will review the Volvo key fob when I am done with the current ECUs and if it is not too complex I will have a go at it as there was a lot of interest for it.

Michael

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Thanks and good luck to everyone. If you run into any issues, just let me know or sent the two keys to me and I will sort it out for you.

Sticker on the front is the best I could find... I have been using the same on the plastic key for some time and it looked ok, but on the CFRP key, I do agree it is not as good. May be on the plastic key it was improving things.....
I thought about an enamel badge of some sort but I was not too keen on gluing something here. Let me know if you come up with anything better.

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Zod said:

Haven't received mine yet. Have all been sent, Michael?

Hi Zod,

I have been trying to reach you on email but I am not receiving any replies. Did you receive the updates email at all ?
I am missing your shipping address. Can you PM me ?

I have shipped the first 15 this week. Yours is part of the second batch to be sent before the end of the month (most probably on Monday 28th).
I am doing them in parallel and I am half-way through them.

Michael

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silverspeed said:

Is it not possible to fit then? Is it not just a case of double sided tape?

For those who need more of the double sided tape. I used the UniBond 'No more nails' permanent strips from B&Q. They have just the right thickness and are very strong. You would just need to trim them to the right width by using one of the metallic side plate as guide for your knife.

Michael

[mb1]

Ok. I have now sold all of the first 30 CFRP keys :-)

I have received more demand and I will do a very last final batch of 15 keys (to the despair of my wife !).

If you are interested, then please get in touch with me as I am already within the last 10.

Michael

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Hello All,

The second batch has been shipped today as planned.

I have a few left on the final batch (I promised my wife I will not do anymore after that....) for end of February.
Just PM me if you are interested.
Grinning, I will email you details later today.

Mb1

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CarbonV12V said:

Finally built mine yesterday.

Fitted the pin badge first - I just drilled the case and then bonded the pin from the inside and super glued from the outside.

Then followed the comprehensive instructions (well apart from giving the transponder a bit of help with a craft knife!).

I had already bought a couple of spare keys just in case something went wrong and may still get one of them coded to the car so I have another spare. I may also cut the spare case down to see if I can get the rubber buttons bonded to work with the carbon key as that would be just perfect.

Once assembled I went to the car to test and nothing . A few flashing lights and a few clicks. Then looked at the battery conditioner as the car hasn't moved since before Xmas and some idiot (probably me ) had switched it off .

Left on charge overnight and now works perfect .

Photo:

Another happy PHer :-)

I still have a handful left to sell from the next (and final) batch that will arrive by the end of this month.
Just PM me to reserve one.

And, yes, I will finally have a look at the Volvo one this week !

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Gdc said:

Did mine today. Drilled a hole for the enamel pin badge. Cut half the pin off, glued. Followed all the instructions and voila 30 minutes later a great CF key. Works like a dream and looks cool too. Its the key AML should have supplied in the first place..not sure what happens when the battery runs out though as the bonded metal side pieces now hold the key together..still its not a problem to worry about today.

Thanks Gdc ! I am really pleased it all went well and that you like it.
The great positive feedback has really been worth the effort :-)

For those waiting for theirs in the very last batch. It is progressing and you should have received an email from me today.

If you are interested in one, just PM me as I have a handful left to allocate.

Mic

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tonyhall38 said:

did you get plaques?

Did you not get my email :-(
Strange...
Yes, I did receive them very quickly after you said they were being made. They are really really good.

[mb1]

Good news, I have finally received the final batch of 15 carbon fibre ECUs today.

So for those waiting for their CFRP ECUs, it should be ready within the next 2 weeks (that's the time it last took me for prepping 15 cases in parallel).

I have a few left to be allocated, so if you fancy one, it will be your last chance as I am not doing anymore after that.

Mb1