morganson's COP S-Type setup

supraguy@aol

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You know the rear-most galley plug- that has the threaded hole in its center for mounting a large hose clamp for the heater core hose? You buy two more of those from the dealer, and install them where the blank galley plugs are. Then just put a stud or threaded rod into them, so that when you install the coil plate, a little bit of that thread will emerge through the top. Then you can put nuts on them, to hold down the plate.
Conversely, you could skip the studs, and install bolts from the top, if you find the proper length.
 

nathaninwa

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IM spending this week and into next weekend getting caught up on the rest of the work I have promised so I can pull another car in to MS for me. Id like to get a count with anyone that is reading how many more covers I should cut. Ive mental noted 3 along the way and 2 of them have been paid for. So just in general, I have enough to cut 12, with 3 being gone.
 

HeWhoOvercomes

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I think I'm one of that three, but here:

HeWhoOvercomes / Jordan S. / Qty-1 / Undermount / 88020

^^and is that spacer made from the 1/2 inch tubing included with the plate?
 

supraguy@aol

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Received my plate in the mail just a couple minutes ago.
Looks fantastic, Nathan- thanks again. Only issues is, that I didn't get any spacers with it.
Honestly, not really an issue. I plan on using threaded rod to mount it, and i'll simply place nuts/ washers at the proper support height.
 

nathaninwa

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ill check the paper work when I get home and I'll refund it. if there was a spacer, it would be taped to the end of the box. I apologize for not including it, I was trying to be careful to not let this happen.
 
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supraguy@aol

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I'll give it a shot, and update/ edit if people see errors:

Morganson DG500 C.O.P. mod:

Coils:
Dg500(long boot) or DG528(short boot). Morganson mentions that long boot fits tighter, though it must be cut down somewhat in length.
The coils have a number of cross-reference numbers as well:
DG500 - DG513, FD502, C1458, DG513, 5C1449, C565, etc, etc...
DG528 - FD496, DG517, E228, F596, C1436, etc, etc, etc.
Again, the main difference is boot length, and some of these may have angled boots- Morganson, please chime in.

Connectors:
They're sometimes listed as" Denso coil on plug" connectors, and I've found a few auctions on Ebay for them. They're used on Jags, Fords, and even some motorcycles.
They have somewhat of a "D" shape to them, with one slot/tab on the top side, next to the release clip. I bought mine from seller: "motorsports_overstock" on Ebay- good price.

The harness requires you to either reuse the oem coilpack plug(4 wires), or purchase a new one. This can be had from Driftmotion.com, and is listed as the CPS plug- same thing.
The other(more affordable) option is to splice in to both side of the connection, ANY 4 wire male/ female plug setup you like. I like the AC Delco weatherpack connectors myself.
Also available for the cheap on Ebay.

Mounting:
Thanks to Nathaninwa, we have a 1/4" aluminum mounting plate that he can provide for a very reasonable cost. It can be set up so that you can mount the coils
above or below, depending on preference/ space restrictions. It mounts to the spark valley, by utilizing the threaded galley plug that you'll find(1) on the rear of the head.
You will need two of these, as there are two mounting holes drilled into the "Nathan plate". However, it may not really be necessary to 'hard-mount' this plate, as once the coils are bolted into in, they really ain't going nowhere.


I will add to this as I have more info.


Coil: DG500


Connector:


Harness plug:


Mounting Plate:


Threaded plug:


*EDIT* It also looks like the DG528 coil has its mounting tab offset differently than the DG500, so that would affect how you set up the mounting plate.
 
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IndigoMKII

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I'll give it a shot, and update/ edit if people see errors:

Morganson DG500 C.O.P. mod:

Coils:
Dg500(long boot) or DG528(short boot). Morganson mentions that long boot fits tighten, though it must be cut down somewhat in length.
The coils have a number of cross-reference numbers as well:
DG500 - DG513, FD502, C1458, DG513, 5C1449, C565, etc, etc...
DG528 - FD496, DG517, E228, F596, C1436, etc, etc, etc.
Again, the main difference is boot length, and some of these may have angled boots- Morganson, please chime in.

Connectors:
They're sometimes listed as" Denso coil on plug" connectors, and I've found a few auctions on Ebay for them. They're used on Jags, Fords, and even some motorcycles.
They have somewhat of a "D" shape to them, with one slot/tab on the top side, next to the release clip. I bought mine from seller: "motorsports_overstock" on Ebay- good price.

The harness requires you to either reuse the oem coilpack plug(4 wires), or purchase a new one. This can be had from Driftmotion.com, and is listed as the CPS plug- same thing.
The other(more affordable) option is to splice in to both side of the connection, ANY 4 wire male/ female plug setup you like. I like the AC Delco weatherpack connectors myself.
Also available for the cheap on Ebay.
I might have missed it and will re-read but are these designed to work with the stock igniter/multiplex system? They don't have the waste fire setup like the IS-300 coils so how could these be wired to the stock system?

EDIT: I found it, some info was updated on the first page. Just to make sure I understand it correctly, you're basically using the 1/2/3 coils as signals for the 4/5/6 coils while running the voltage to the 4/5/6 coils. Essentially making it run like a waste coil setup.
 

supraguy@aol

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Yup. Exactly as the oem coilpack works, to my knowledge.
Grim Reaper is working on an ignition controller, so that we can do away with multiplex, and improve dwell times by using a better igniter option.
 

morganson

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Excellent compilation. All information is correct. The coil to use is the dg500 straight boot staight plug as it makes an easy and clean boot cut and clears all pipes. That is the same denso plug i get so far the best anf most reasonable to be had.
The current setup is still fired like the waste spark its just easier on the coils to have the six individual units. And as has been shown by grim other than not utilizing the coil to its fullest it still puts out more spark than both the is300 and factory coils.
I want to thank everyone who has chipped in time and effort to bring this to the point we are at now. This has been a huge step for the mk3 platform. I want everyone to know AbsoluteSpeed and Nathaninwa has had just as much to do with this as i have.
 

supraguy@aol

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I would like to make mention to Nathan-
I have measured the two mounting holes in the plate to be approximately 7 3/8" apart, center-to-center; the actual mount points
in the head are approximately 7 1/16", center-to-center. I am simply going to drill out the two holes to make it work, and just cover the wider holes with a washer/ nut.
I ask that Morganson please double check my math on an actual head, vs. the cad diagram specs. If a new distance is actually needed, it would be of benefit to have this confirmed before Nathan makes his next batch.
 

nathaninwa

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morgnason, supraguy, can you tell where the holes need to get moved too? There a little off in the first test one I did that was to thin before I modded the drawing. But without the coils to test I dont know where to move the holes to so the coils still fit good.

Edit, looking at the plate, it seems as if the aft hole moves forward 3/8 inch, it would be in the same location to the tapped 6mm as the front one.
 
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supraguy@aol

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morgnason, supraguy, can you tell where the holes need to get moved too? There a little off in the first test one I did that was to thin before I modded the drawing. But without the coils to test I dont know where to move the holes to so the coils still fit good.

Edit, looking at the plate, it seems as if the aft hole moves forward 3/8 inch, it would be in the same location to the tapped 6mm as the front one.
Not really sure. I moved both holes inward about 3mm each, and that did the trick. The new issue that I'm dealing with, is how to mount the throttle bracket assembly.
I'm probably going to have to cut a full cutout on the driver's side of the plate, then put some threaded rod into the mounting hole, once the bracket is in position.
But it's coming along.
 

supraguy@aol

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PS- Here's a couple of pics of what I did:

Cut about two inches of boot off, and cut the springs exactly in half.





Undermounted mine, and bolted them to the plate from underneath. This way, I can remove the entire assembly in one piece. I added two washers between the coil mounting surface and the plate, so that I wouldn't have to flatten the curve of the flange with a grinder.

 

nathaninwa

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I wonder if each coil is radius just a bit different? I could take a little more lateral away. The coils I used were "standard" and an accel unit.
 

lithium14

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I tested to see how tight the boots grip the spark plugs... you may want to reconsider trying to remove the entire assembly in one piece. I highly doubt it's gonna happen lol.
 

TrqMnstr

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...........Undermounted mine, and bolted them to the plate from underneath. This way, I can remove the entire assembly in one piece. I added two washers between the coil mounting surface and the plate, so that I wouldn't have to flatten the curve of the flange with a grinder.

Do you think you would get much flex on the coil when removing the assembly?? It just look like under mounting it would allow room for flex which could result in braking. Or is the coil mounting hole thick enough?
 

BryanDyer

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Nathan, these are pretty awesome. It's nice to have someone who takes there spare time to help out the mk3 owners! Can't wait to see my bracket! :)
 

supraguy@aol

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Do you think you would get much flex on the coil when removing the assembly?? It just look like under mounting it would allow room for flex which could result in braking. Or is the coil mounting hole thick enough?
Because I cut the boots off at the bottom, they are not a vise-like grip on the plugs, so I don't think it's as much a concern as it otherwise would be.
 

nathaninwa

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How much to 29483 and I won't be ready till March and would like the under mount and need 2


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To make things eaiser, all plates are getting ground from this time forward. Makes the process of bunches go alot easier. For this next group Ill still do the 28 per plate with 1.00 for the tube (if anyone can get me a close length I can cut 2 of them just about to size) and shipping to morganson was almost 15.00 for the 2 he got. So the most would be 58+15 for 73 shipped on 2 plates and 2 tubes.
 

morganson

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Got mine started finally. Some pics for the stud mounting and polished love.

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And then some pics of the production harness. TrqMnstr can tell you how nice these are.
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