Automotive

A colleague of mine recently bought a Golf. A blue Golf. He was thinking about getting an A1, but didn’t like the loud colors. This from a guy who wears purple plaid shirts to work.

Southern Germans, specifically Audi, basically invented the boring silver car that seems to drive the perception of and image of German people in the US. The real reason for the silver cars is that most German execs don’t want to be seen driving flashy cars, to the point that they will order the boring silver car with the badges removed. No chance at identifying it as better than anyone else’s, that might attract envy. Whatever. The only other color Audis seem to be available in over here is trash-truck orange. I don’t get the dichotomy, but I do love it.

image credit autoblog.com

image credit autoblog.com

German people are a colorful dichotomy in every part of their lives. They decry the possibility of sharing personal data, but give out their bank account information like candy on St Martin’s Day. They don’t want to be seen, but dress in beautifully colorful and creatively designed, extremely close-fitting clothes. Which they happily remove completely at sauna. They are the first to blur their license plates and house numbers on Google Maps, but they drive bright green cars which they park directly out front. Have I mentioned the number of personalized license plates? They are everywhere!

I love the color. I love the patterns. I love the lack of grey in daily life in Germany. I love the close-fitting tailored clothes. I love the fact that the typical German person takes the time to carefully choose what to show and what to hide, rather simply hiding everything or showing everything, like we do in American culture. Let’s face it – if you are worried about your thighs in the US, you wear a grey suit cut like a flour sack to work, regardless of the fact that your upper half would make the cover of Vogue. Here in Germany, ladies pay little or no attention to their less-stellar-looking parts and focus on drawing attention to what looks good or even great. Guys are the same way – dressing for what works, rather than for what doesn’t. And the color! Did I mention the color? Or the prints? Or the plaids? Oh, fabulous!! There is a reason Desigual is beloved here.

desigual aw10

Before I left, quite a few colleagues mentioned that I would likely fit in much better in Germany due to my clothing habits. And I did. Then I went even further. I put aside all of my grey sack suits and I bought a hot pink suit that is cut just so. I customer ordered pink and white motorcycle leathers. I dropped a small fortune at Desigual, and I have a few more items in mind to grab before I leave. Oh, wait, I’ll be back, so there will be no end to my Desigual habit, I think! It drives my American colleagues nuts when I and my attire walk into a room. I no longer care – I am sorry that they are afraid to look awesome. I am not any more.  I am no longer ashamed of my body or of my colorful sense of self. I will continue to use color for purpose.

I am contemplating replacing my old blue Passat with a froggy green Golf one day. Or a yellow Elise. Yes. A yellow Elise sounds just about perfect.

It doesn’t sound too hard, does it, to buy a pair of coveralls that fit? Well, I am female….

Years ago, I purchased a pair of navy blue size 38 regular Dickies coveralls for use around the house and garage. They got about 10 minutes of use before they were ditched for old jeans and a ratty tshirt. Why? Remember what I said about coveralls that fit?

Admittedly, there aren’t quite as many women wearing coveralls as there are guys out there, so it’s no surprise that a decently-fitting pair is hard to come by. Add in that a fair number of the women out there who do wear coveralls aren’t built like Lauren Bacall, and you have a market that isn’t all that attractive to coveralls makers. Because it consists of about four total women.

The difference between coveralls for men and coveralls for women is easy to spot. Women’s coveralls have room for boobs and butts. They also have shorter back-waists – the distance from the collar to the waistline. Mine went into the bin-of-things-we-don’t-know-what-to-do-with because minus the boob and butt room and being too long on the top, I was spending more time adjusting them than a Major League Baseball player spends adjusting his you-know-whats.

Last summer, I was going through that bin and pulled out the coveralls. Hmm, project? Sure! I’d already re-sized and significantly altered a two-layer Nomex suit for racing cars, how hard could a pair of coveralls be? The good designers at Dickies were a lot more serious about these things staying together than peeps over at Speed Sport Racing! The coveralls took me over eight hours simply to dismantle to the point that alteration could begin. Adding to the mess was the most complex elastic waist I’ve ever seen, one that requires a special machine to properly install. I got the bulk of the fitting done over the next few weeks, but the elastic waist and its complexity beat me, and I put the project on hold for a while.

Until today.

Alterations are typically bread and butter work for a seamstress. Relatively simply even when complex, and rarely requiring more than a few pins here or there to set up seams. Occasionally, you get something over the top, and you have to resort to machine basting. At the very tip-top of annoying and difficult seams come the ones you have to hand baste – sew by hand before you sew them properly with a machine. I had set aside the annoying elastic waist when exuberant pinning did not solve the problem. Sometime in the winter, I took a stab at it with machine basting. Today, I sucked in a lot of air and got out the pin cushion and thread: I would hand baste this thing and finish it off. Four hours later, three spent out in my garden in the sunshine, and I was rewarded for my effort with a pair of very stock-looking, properly fitting coveralls.

They look completely off-the-shelf. I like that. I just wish they had been off-the-shelf to begin with!

It’s one of my favorite literary lines ever, from Michael Crichton’s The Andromeda Strain. The scientist in question is pondering whether successful treatment of the symptoms displayed by his patient means that the disease causing them is actually cured.

So it goes with electronic diagnoses involving logic boards. Stray voltage at one pin results in a strange signal at another one. The voltage can have three sources, but which one is it?

For example, a artificially high (500rpm) tach reading on an F650GS that remains after shut off for several seconds. Coupled with poor running/starting. Symptoms occur only when bike is started wet after cold rain. Brought up to running temp and restarted, the problem is gone. Signal path is a single star circuit of the ECU, the #1 coil, and the tach signal feed. Diagnosis starts with check air and fuel to rule them out for the poor running aspect. Both are fine. Second step – pull plugs. As expected the #1 plug is funny looking, not bad, but a bit pink on the insulator. The primary resistance on the coil is a hair high when the coil body is wet.

Is this a symptom, or is it the disease? I’ll find out when I pull the tach apart. I hope.

All my life, I’ve been pretty good about patents and trademarks. So I’m a bit confused as to why BMW isn’t. The “Motronic” in my bike is actually a Hella product called BMS, as I just learned from the FAQs over at f650.com. This explains a great deal about why it bears so little resemblance to a modern Bosch engine management system, even as it bears resemblances to pieces of so many others.

Did I say anything about wanting to learn a new EFI control codec? No, I did not.

edit – when I wrote this post, I was under the impression that Motronic meant Motronic. Not to BMW, who call any engine control unit Motronic, regardless of whether they are violating Bosch’s trademark rights or not… See above.

I am a card-carrying K-Jetronic girl. When I first discovered K-Jet-E in my 1982 VW Rabbit Convertible, I leaned back in awe and remarked to myself that this is how I would do fuel injection if I had to: I would take apart a carburettor and distribute its parts liberally around the engine bay, making sure that each had its place and did not interfere with the others, all being individually adjustable and controllable (einstellbar und kontrollierbar, auf Deutsch). Just like K-Jet. I regard K-Jet as one of the peaks of elegant engineering design, and certainly one of the coolest systems to ever leave the halls of Robert Bosch Gmbh. It is also simple and easy to work with, provided you understand the basics of air/fuel ratios and a few other odds and ends about ICEs, of course.

I can’t say the same for Motronic, Bosch’s “modern” EFI control system. I’ve been watching a weird problem on my bike lately, and I’ve tracked it down to what looks like a bad hack job over in the Motronic design group. Not content with just supplying a modern, 2004 version of Motronic, it appears that Bosch decided to crib together the lousy parts of Motronic (signals taken from only half of the system), an interesting part of K-Jet (running the whole thing off the coil sense), and who knows what from Digifant.

The problem manifests itself as a flat 500rpm lift in the tach signal when it rains. Being Motronic, the tach signal is fed from the coil sense, but only from one of the two coils. The Rotax engine is known for some assorted issues (other than being a bullet-proof, workhorse, dinosaur of a fuel-efficient and otherwise great motor), one of which is pretty serious surging. Well…. imagine that. When your injector circuit is being driven by a feedback loop from half of the coil circuit, and voltage is building up due to phantom capacitance somewhere, yeah, the poor thing is going to surge like crazy.

So, I’ll be spending my weekend working on the bike with the only tool you need on a Motronic machine: my DVM. This is not what “working on the (insert ICE-equipped vehicle)” is supposed to mean, Mr Bosch…..

There will be new content interspersed with old content for a while…

It’s weird to do car diagnostics from no where near the car. Email diagnostics were taken to a new level with one of the old Golfs – a Brasilian Golf IV TDI that had massive electronic issues. After throwing parts at it for two months under warranty, I called in the help of a trusted friend and VW tech, emailing the longest list of codes I had ever seen: 174 in total. The solution, according to the friend, was to search every ground lug in the car out, and check it. This is a seven hour job, and the dealer was not interested until I threatened to lemon the poor car. I did not want to do that, but hey, it worked. The culprit ended up being a $1.50 acorn nut that was loose on the ground point under the battery. For nine more years under our ownership, the car went without a single problem that could be traced to bad electronics. Actually, it went without any problem that could not be solved in an hour in the driveway, or a call to the warranty office. It was a good car, afterall.

I purchased my Passat in March of 2000 from Devon Hill VW in Devon, PA- they are good guys! I took delivery on the 24th, and I have been enjoying the ride ever since.

It is Indigo Blue with a grey velour interior. It has a five speed manual transmission with the 1.8 litre turbo engine. It came with the luxury package of a sunroof, rear tonneau, and Adelaide wheels (I like them!!). I also purchased the CD-6 changer to go with the Monsoon head unit. I got the CD-6 as a peace offering to my spouse since he wanted the Tip! I also have the VW roof rack crossbars.

My first mod was a customisation. I replaced the shift knob and boot with a gobKnob bubble ball and a custom boot which I made myself. I have a pattern and instructions for those who wish to make their own boots, too. The shifter shaft is an unusual thread- 12mm, 1.5 thread pitch, so you have to get a special tap! Dad machined out the stainless steel fitting which screws onto the shaft. I am planning a surprise *upgrade* for this spring to this knob system. Keep checking the forums at clubB5 for more on this!

2/01 – I recently swapped out the rear interior light for the switched version. This is the same reading light that is found over the rear doors in the cabin. The part cost $22, and the install took about 2 minutes. This is very nice for late night grocery runs with the kids- you can turn off the light and let them sleep!

4/01 – The AlienWindow remote window controller is an excellent modification to make to your car. It allows you to control the windows from your VW switchblade remote. I just did it, and it’s great! It took me about one and a half hours to get done and was a good afternoon project. I took some pictures of the install while I had the car apart.

5/01 – My Euroswitch has arrived from the Pottermen! What nice people out there in CA, they sent me M&M’s with the part. Order from www.parts4vws.com. I have installed it, now I must run the wires for my rear fogs. I also explored the underside of the dashboard – kind of a pain to get into, but there are many goodies underneath there! Including relay 173. I expect to be removing that soon, when I finally convert to clear corners and those fabulous PolarG blue bulbs!

Rear fogs are in! I had some trouble with the wiring, You must go up and over the hatch in the variant, something I did not anticipate when I soldered up my wiring harness. You need 20′ of wire, 13 feet from front to back, and 7 feet from side to side. I have caught some flack for wiring up both sides, but I think that it looks better. I am also thinking about slaving the brake lights into the fogs with the dual diode arrangement, so I need the wire over there anyway. I also hooked up the dash indicator. This was a bit difficult as I had trouble with the plug in the back of the tachometer. It was difficult to get out. But, done and over with, so I am happy.

I added the sunglass holder also this month. Unfortunately, the dealer was only able to get the Passat (3B0) part, so I am stuck with the chrome strip. It doesn’t look as bad as I thought it would in my otherwise chrome-free car.

I’m Katherine, and I’m a chemical tribologist in the metalworking industry. What’s that? A chemical tribologist is a chemist who studies friction and wear. I became interested in this field when I was a co-op student at Drexel University. I co-oped for Apex Alkali Products (now RichardsApex Company), where I learned the fundamentals of lubrication as it applies to wire drawing processes. The work was so interesting that I stayed with Apex for long after my co-op cycle was over! I began to work on lubricant development projects and use bench testing machinery. It was very exciting to see the chemistry I had learned in school in action.

The funny thing is, this all started long before college, or even high school. As a little girl, I had the opportunity to visit the new foundry of the New York Air Brake company (now Knorr Brake). My father is a mechanical engineer (everything in life is a force balance!), and was part of the product design team at the Air Brake. The children on the tour got to do some of the things that the foundry workers did every day. I got to make a sand cast of a complex pnuematic valve assembly. This involved pouring the sand and pressurising the mould. I then inserted little styrofoam blocks into the sand cast to support it under the weight of the molten metal. I put the sand cast onto a conveyor, and followed it to a platform where I was directed to pull a large handle- it was as long as I was tall! The parts came out of the other end of a large machine, and we follwed them around the factory as they were machined and fitted out. Many years later, I realised that I had pulled the ladle and made an iron casting. It was a long time before I figured out what each step of the process was for and what I had actually done, but from the day of the visit on, I was completely fascinated by manufacturing and big metal. The foundry experience shaped my life in ways I wouldn’t appreciate for over 15 years.

After 2 and a half years at Apex, I decided to finish my coursework full time. I left Apex for a year of intense study and graduated from Drexel University in 1994 with my BS in Chemistry.

After graduation, I joined Houghton International, a leading independent manufacturer of metalworking fluids. This is where the fun really got going! I started in the Fluid Power group, learning about hydraulic systems and their lubrication requirements. That didn’t last long, as an opening turned up in the Metal Forming group. Metal forming is the chipless deformation of metals- and wire drawing is one of the many processes that fall under its umbrella. I was right at home!

While working at Houghon, I had many opportunities- I completed my MS in Organometallic Chemistry at Drexel in 1998, and passed my candidacy exams for PhD in January of 2000. I hope to complete my PhD one day. I have also published several research and technology papers (see list below). I have become very involved in the development of new lubricant testing methods which provide more representative pictures of the lubrication system at work in a given process.

I worked with several processes at Houghton- non-ferrous (aluminum and copper) wire drawing, steel wire drawing, hot and cold forging, cold heading, deep drawing, stamping, fine blanking, rolling, extrusion and many other low metal loss processes. I occasionally worked with sintered metals and die casting. I was asked to design lubricants for each of these processes. This required a complete understanding of the process and its lubrication requirements. My mechanics background came in very handy with this part of the job! I then mapped the process by determining the simplest configuration of testing pieces which will give an accurate representation of the conditions of the metal/die contact I was studying. I also developed test methods for the bench tester I planned to use. Some of the testers I used are the Falex pin and vee block rig, the 4-ball EP and 4-ball wear, the ball on three disc, and the Reichert device.

My favourite project is the development of specialised lubricants for the wet drawing of steel filaments. I hope to obtain a patent on this work.

After 7 great years at Houghton, I was approached by Arizona Chemical Company, the chemicals division of International Paper to take over their metalworking program. Arizona takes waste streams from the kraft paper pulping process called black liquor and refines these wastes into pure fatty acids and fatty acid blends. Nearly 30% of the material is made of rosins and rosin acids These important materials play a big role in metalworking by forming strong films which support heavy loads.

I was doing research to study how Arizona’s products can be used in metalworking. It was a lot of fun, and was the opportunity I was looking for to do molecular level development work. Arizona is in Savannah, GA, a beautiful southern city with a lot to offer!

Now I’m at Henkel Corporation outside of Detroit. Back at home, if you ask me!

To learn more about tribology, check out the Society of Tribologists and Lubrication Engineers and the American Society of Mechnical Engineers.