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1mm would be way too thick. Most paints go on at 1-5 mils. Anything more than that and it will have a thermal impact.

http://www.supramania.com/forums/showthread.php?147334-painted-intercooler&p=1752177&viewfull=1#post1752177

Welcome. We could use some help on the app side of things, so I am hoping this works out for everyone.

Absolutely, the environment plays a huge role. My car is rust free, including the wells, but I live in a region with no salt, low humidity, and not much rain, as long as I remember not to park beside the lawn sprinklers!

When the mk3 was built, the automotive industry had switched to electrogalvanized sheet metal. This stuff has a layer of sacrificial zinc on it to prevent rust. Once that zinc gets used up, rust starts unchecked. I believe the extensive internal rust some of you are experiencing is due to...

You're right, if the compressor was undersized your pressures would not be as they are. I don't buy the radiator argument either, because your subcooling is fine. It may be that you are simply loading the system beyond its design limits. A superheat of 70 deg definitely supports that...

Anodized aluminum is not good for thermal transfer (it is a coating of AlO2 (alumina) which is a piss poor thermal conductor. Same with paint. The only reason you don't see a big effect is because it is thin. Also the color is irrelevant. The contribution of heat transfer from radiation...

I would check for a code 51.

Disconnect the mag clutch connector and see if it blows after ten minutes. If it does not, then the clutch is the probable culprit drawing too much current. That could happen if the winding insulation has become damaged. Measure the clutch current draw to be sure before replacing.

Seems to be working okay, but the meter is too small for the job. The load is 100% from 4000rpm on. I believe the MR2s do something similar.

The ECU will take 3 seconds to go open loop when the load exceeds a value that is a function of rpm (44% at 3600 to 0% at 7600 rpm). That may be the delay you are referring to. There are some conditions where the open loop delay is eliminated such as: coolant < 45C, rpm > 6000, throttle open...

Yup, the standards tightened this year, but not for all model years! See this post. http://www.supramania.com/forums/showthread.php?146219-Emission-specs&p=1741929&viewfull=1#post1741929 To bad the state cancelled the "test only" consumer assistance program. That would have given you an easy...

The stock downpipe and elbow will fit where the BIC goes for the purposes of the test, unless he has something other than a CT26 flange. My car is also a federal spec car and it passes the CA smog test. The main differences between a CA spec and Fed spec GTE are the additional...

You want a 30 minute drive to get the oil hot and drive out any fuel that has gotten in it. You also want time to purge the evap canister. A 5 minute drive is not going to do it. The car should pass with the factory timing with plenty of margin. If you have the precat, putting it back on will...

Save your money on the O2 sensor, you're car is running stoich and is in good fuel control. A/F at 15mph 14.643, and 25 mph 14.701. I presume the precat is gone on this car. I would try fresh oil, a long high speed drive before the test, and avoid long idling time before the test. Put the...

You are not listening. There is a high probability you are going to buy a cat you don't need or want. Spend $39 for a pretest and get the numbers, if your uncle's friend won't give them to you.

I'm not familiar with the VR circuit in megasquirt. The CPS signals have a pretty wide dynamic range from idle to max rpm. The factory ECU uses a diode clamping circuit. Does the VR circuit have something similar?

What kind of signal processing are you doing on the CPS signals before the MCU?

I'd start at the ECU side.