So to finish this project and thread off. The owner ideally wanted the engine to run on the factory COP coils. I made a interface unit to trigger the coils from the outputs from the dfi. It runs even smoother now although the coils do get hot can hold you finger on them but definitely warmer then I'...

So I had one last look at this today. I ended up using a VY abs sensor as the pole was smaller then a vt one. Measured around 1.7k ohm. Got that installed with a 0.2mm air gap and got a decent looking waveform with 7v to over 10v on the peaks at cranking compared to less then 1v it was before. Plugg...

I think I most frustrated by the fact I could hook pretty much any aftermarket ECU with a configurable trigger and be able to use that waveform no problem. I've seen way way worse that needs some pretty heavy filtering and they just runfor for years and years

Didn't attach

From what I can tell the zetec CAS is almost 7mm wide so that's probably alot of the reason it's not getting the small gap between the sync tooth well. So I made all the teeth abit more narrow 3.5mm down to 2.5mm and tried my best to get it spot on spacings etc. Re positioned the CAS to get the air ...

All great info thanks guys. I think first plan is to see if the sensor is in the right orientation and the try to find out how wide the pole of the sensor is vs my tooth width. Then after that make sure between the teeth are as smooth and concentric as possible. Then start to narrow the tooth width ...

Oh and I'm using a ford zetec CAS atm as it just fit better packaging wise and had exact same resistance as the stock Jackaroo CAS

What is considered to low a voltage? It's between 0.7v and 1v at cranking speed. Is that ballpark or? Yeah I forgot about that I tried it with the VT abs sensor and it didn't seem to make alot of difference but that was before I had the scope. If it is 90 degrees out is it possible the field is to &...

Yeah that's what I thought too. But unsure how to go about fixing it. The trigger wheel teeth are like the ones on the template but maybe not quite as high. It's like the sensor isn't picking up the slot between the teeth well enough? Given that all the the others seem to have good signals I don't k...

Going off the peaks on the scope it's pretty good not a heap of variation. The sensor airgap is 18thou on all the teeth from what I measured maybe a couple were a tad tighter then others but I couldn't get a 19thou feeler gauge in them so must be hardly any