Custom fly by wire? (Phils 4agte AW11)

[Phild0]

Hey all, having troubles with the throttle cable in my AW11. The original problem is this:

The cable runs from the pedal into the front bonnet, under front bonnet, back along fuel tank, into engine bay, around the air vent side, past the inlet manifold and onto the 4age throttle body.

The stock cable as we know come straight into the engine bay, up a little and pulls 90 degrees CCW to the direction i need to now, and wasn't long enough. I sent mine away to get lengthened (about 1m) so now it fits however it's introduced a new problem:

Pressing the throttle requires HEAPS of force and feels/sounds like grating a carrot along concrete. I can only put this to a too longer cable with too many/sharper turns.

Solutions? custom FBW? has anyone done this a different way before?
All suggestions appreciated. Excuse shit photo.

-Phil

[Radar]

Don't you mean drive by wire?.

[oldcorollas]

how did they lengthen?
new inner and extended outer? or all new inner and outer using just the original end bits?

sounds morelike they used crap materials/methods... perhaps?

how sharp are the bends?

[brett_celicacoupe]

get a motorbike shop to make a brand new cable.

at a motorbike place i worked, we used to have the inner, outer and end fittings and just make cables to suit anything.

your going to need plenty of grease in there either way. something like molly grease would be good even though its messy

[roadsailing]

You could try a hydraulic one, would be a bit weird though.

don;t go to drive by wire, I looked into it a while back and getting a new throttle body fixed everything (ie dont jump to conclusions)

[Phild0]

cool, alright - so yall think its more a problem of bad parts/installation.
will ass around a bit more and keep posted.

[pandaah]

id suggest taking your cable out and bench testing it, maybe you can just lubricate it, also try securing the cable in more places so it doesnt flex while its being used, thatll make it stiffer if the cable is trying to move while the inner cable is moving

[wa5]

should you choose to go Hydraulic as has been suggested, be very very careful where you mount your piping, IE keep it away from any heat sources... Hot oil expands, not good in a closed system that controls your throttle...

[Cuzzo]

Is it a street car or track only?

Street = set it up like factory? unless the TB is in a non-factory location?

[wagonist]

I echo OC comments.

I once tried to get a handbrake cable lengthened. The cable place didn't even want to know about it because the join needs to be outside the shielding ( because the join is larger), and then you need to hold both sides of the shielding rigid so that the cable keeps moving.

It cost me about $100 to get 2x 3m long cables made with the ends I wanted.

Why can't you use a stock AW11 cable?

[Phild0]

Stock throttle arrangement wont work because of the GZE head - rocker setup was a bit different and the tripod style pully system doesnt fit. Wonder if a set of GE rocker covers would enable this.

Unsure of how it was lengthened.. i can only assume a new inner.. cost $100 odd.

[JP]

GZE and GE Heads are identical (when within the same family, ie bigport or smallport). The cam covers and other accessories are interchangable.

If for some reason you HAD to go with a different style of throttle actuation, you could use something like a pedal assembly from a falcon along with it's throttle body, and then use the electronic throttle controller from www.tfelectronics.com.au

[wagonist]

How long ago was the cable done?
The noise & resistance will be due to the cable catching on the outer sheath. This will cause the cable to break as it is under strain.

I'd be going back with the car to the place that lengthened the cable with a "please explain"

Alternatively, source an AW11 GZE throttle cable.

[MR22ZZ]

GZE and GE Heads are identical (when within the same family, ie bigport or smallport). The cam covers and other accessories are interchangable.

If for some reason you HAD to go with a different style of throttle actuation, you could use something like a pedal assembly from a falcon along with it's throttle body, and then use the electronic throttle controller from www.tfelectronics.com.au

Jason, do you know if it would be possible to put a 1ZZ fly-by-wire throttle body on and how hard it would be to get a stand alone controller for it seperate from a 1ZZ ECU? I know you've done a hell of a lot with the 1ZZ and 2ZZ systems just don't know how much you've played with the fly-by-wire systems. Just thinking that the throttle body would be a comparible size to the 4A one.

EDIT: just had a look at that link, that's exactly what I was asking, cool. The stand alone controller to match the Subaru TB would probably be a good size.
http://www.tfelectronics.com.au/Page...lecontrol.html

[JP]

yeah, you could use the 1zz corolla setup if you really wanted, still need to do fabrication to fit the pedal and throttle. Would then also have to figure out the PID for the controller.

The 2zz throttle body is larger than the 1zz, I'd have to go to the shed and measure then if you want specific sizes.