Complete Surf System

I received the PCBs last week to build the main controller as well as the relay driver.  I've found a few required changes, but I do have communication between the 2 boards working!  I'll do some additional testing and implement the last few features before ordering the final boards, likely in a few weeks.

Complete Surf System

The PCBs arrived today.  I have the first one soldered up and running on 12v power!  I'm hoping I can find a GPS simulator I can use for development, so I didn't put a real GPS module on this board.  I plan to solder up 1 switch circuit and one relay circuit on the relay driver tomorrow to make sure they work.

Complete Surf System

I have the PCB designs for the Complete Surf System done and ready to send off for manufacturing.  This is the main controller that runs all the logic code and drives the display.  The GPS, and circuitry for reading the level of the ballast bags with a pressure transducer, gyroscope and tach/fuel inputs are also on this board.  This board will mount on top of the relay driver board.

This is the relay driver board.  It gets a signal from the main controller board and controls the relays that are used to fill or empty the ballast bags, extend or retract the surf devices and extend or retract the wake plate.  It also has the circuitry to ready the state of the manual ballast switches, so the main controller can keep track of how much weight has been pumped into or out of each back manually.

 

Complete Surf System

If you have been following this, I started a Perfect Speed project a while back and have not posted an update in quite a while.  That project has turned into MUCH more.  It will actually control the entire surf system on the boat, ballast bags, surf gates & tabs, wake plate and boat speed.

The system has support for rider/sport profiles.  It will store settings for 8 riders and 3 sports each, surfing, wakeboarding and waterskiing.  The system will automatically save all the setting whenever they are changed.  Profiles are restored by picking the name and sport from the dropdowns at the top. 

In Surf mode, the gates and tabs extend above 5 mph and retract again above 15 mph.  In wakeboard and waterski mode, the gates and tabs automatically retract fully, but the wake plate and ballast bag remain tunable as well as boat speed.  In waterski mode, the inclinometer also disappears. 

Finally, when you are done for the day, you can turn the system off and the wake plate as well as all the gates and tabs will fully retract.  The ballast bags will also fully empty.  The green/red progress bars tell you the direction things are moving.  Orange tells you they are not currently in motion.

Fresh Air Exhaust

The down pipe is finished and tacked onto the main pipe.  I still need to make the support structure, but I think I will build the new swim platform first.  Because I have never welded exhaust pipe before, I'm going to have to have the final welding done elsewhere.  Next up is the muffler delete.

Fresh Air Exhaust

I started building a Fresh Air Exhaust for the boat late last year, but I've been really bad about posting stuff on this blog.  I have the main pipe finished.  So next is the make the down pipe.  I'm going to start with 3-1/2" oval pipe and squish one end back to round and the other end to a tear drop shape.  
 

Fuel Injection

Today I was able to get almost all the wiring done.  Because I spent so much time this winter setting things up, I was able to knock this all out in just a matter of hours.  I still have the crank position sensor and the fuel pump to wire up, but I need to mount them first.  Then I need to clean it all up with some wire loom.