How To: Build a Haltech Nexus R5 ECU from scratch

[@IcECreAm-sv2qv]

These are the types of videos that may not reach the farthest engagement wise, but to the people who watch it, we will learn invaluable lessons. I hope you inspire others to create amazing vehicles the same way you inspire me! Thank you Rob

[@ToxicMrSmith]

What did you learn from this, that was invaluable to you?

[@DomBounty]

The fact that these guys are manufacturing all of this in house is amazing, all of this equipment is worth a lot of money, and most companies would out-source all of this to china & tiawan!

[@Low760]

Lockdowns forced then to go in house even more.

[@asfandsayyam5185]

I recently built an open source standalone ECU for my e36 called speeduino and have started on a personal project to build my very own standalone ECU. This sort of information is extremely valuable for the right type of car-enthusiast. Man do I have a long way to go

[@luukvanoijen7082]

how was your experience with the speeduino? also, how do you know where to start with making your own ECU? this is something super interesting to me as well, ive beeen coding for years and have some basic microcontroller knowledge and i obviously love cars, would be sick to combine them all :)

[@Low760]

There's a massive difference between a nexus and a speedduino. Even to megasquirt, especially with the ms3 pro mini.

[@luukvanoijen7082]

@@Low760 of course, but the guy didnt claim they were similar in capabilities lol

[@lasskinn474]

@@luukvanoijen7082 take a look at an open source thing like speeduino. the timers/interrupts stuff is the hard part to get right. because the ecu is all about timing. the faster the microcontroller the more leeway you have to be stupid with it (8mhz vs. 300mhz has a world of difference in how well your stuff has to be designed for it to be able to run a 6000 rpm 4 banger). another well discussed venue for many of the things an ecu can do is 3d printer firmware and dev discussions about them. usual arduino sort of projects don't cover that side at all usually. those spinning led persistence of vision propellers with leds on them that paint an image in the air are sort of a bare bones ecu visualized tho..

[@zachogdahl210]

Speeduino is really cool for 4 cyl cars and is unbeatably cheap (i built mine for 150 usd). But if you want a more advanced diy ecu there is rus efi which has a lot of community made plugnplay boards for different engines! My biggest gripe with speeduino is no knock sensor capability

[@thewatcher6794]

Rob Dahm I used to work in the SMT industry and I am here to tell you that the SMT industry has been doing it that same way for over 40 years , which means yes it was even done that way back in 1983 when you were born

[@wobblysauce]

Now smaller and faster.

[@jeremyglover5541]

yeah. I was sitting here thinking this, but resisted saying it, as he is so clearly excited about it. That said, the inspection setups at that point would not have been anywhere near this level.

[@justion337]

They finally got Rob to pronounce Haltech correctly, lol.

[@Powertampa]

Visited Haltech, made an appearance on the Unicorn Circuit and you survived the drop bears, good job!

[@somewhatofaprofessional7940]

I had no idea haltech actually does everything in house with their own pick-n-place machines. That is absolutely amazing!!

[@lasskinn474]

it makes prototyping a breeze. also helps with clones being harder to produce since you're not just giving all the design(edit: files) out of house to some subcontractor.

[@jeremyglover5541]

Thanks for this video Rob. As an Aussie Car lover who is also involved in short run PCBA design and manufacture (mostly get the bare PCBs produced OS, but some early prototype boards here) for my own audio DSP startup, it makes me proud to see that companies like Haltech are still able to exist here, with so much tech manufacturing headed offshore. I have a much smaller small run prototyping/production setup at home, with reflow, inspection and also 3d printing and laser cutting for chassis prototyping and some small parts. Next tool I plan for is a pick and place; at the moment I still place the components by hand, after the solder stencil/paste is applied and I use a mix of hand solder, hotplate and oven reflow for finishing the board.

[@mansalans]

Using a drill to send in the screws into a PCB is absolutely wild. You could see all the metal shavings all over the bit as well. Wild scenes to see for such a big company.

[@jonty3000]

Also finger prints all over the plastics is the worst. I know I'm a nerd and get finger prints everywhere.

[@A_lesson_in_Hate]

Wild hay? They have just about zero failure rate so I think they know what there doing.

[@mansalans]

​@@A_lesson_in_Hate I know way too many people that have had to return haltec ECUs for fault testing

[@mansalans]

@@A_lesson_in_Hate I've personally sent back 2 ECUs with faulty grounds.

[@Baube418]

@@A_lesson_in_Hate I sent an ecu for cold solder joint

[@fpfree8821]

One of my early cars here in oz was a ke30 two door Corolla that ran a 2tgeu with one of those early haltech units. A happy little 1600 8v twin cam Yamaha designed motor that enjoyed being beat on daily. ECU came with floppy discs and needed an ancient black and green screen laptop. I dummy wired the factory ecu so it looked like it was running the factory one for inspection for the street. PowerFC does the duty in the s14 these days. Car scene wouldn’t be the same without either of them. Kudos.

[@ZLAKLR20B]

It was pretty cool to go through Haltech and see this process first hand. Amazing what they do in such a small place, and the volumes of ecus made and sold blew me away

[@Low760]

The head company soon will be making them in China for the rebel and such for the volume required.

[@ZLAKLR20B]

@@Low760 no they wont be, they have the capabilities right there in ozzy

[@aaronb1320]

@@Low760 no we wont be

[@I-0-0-I]

Brrro, even if you only went to Oz to make this video, it was totally worth it to spread the message of how amazing these guys are. (some dude in Poland)

[@Low760]

He went to world time attack.

[@cam.venice]

This was a super cool video to watch. Didn’t expect Haltech to do it all in house. Kinda awesome and makes me like them even more!

[@chriswagner9573]

Working in the electronics MFG industry, it’s incredible to see others witnessing how immensely small and intricate these parts are that run our daily electronics

[@AndersVestlund]

Awesome to see more in-depth of the process, Haltech is 100% going in the right direction with the approach to do everything in-house. Well done and thanks for the video Rob!

[@Hafu_JP]

Never thought I would see Rob dealing with stuff I work with. Smt looks way more interesting when other people are talking about it.

[@mmosquini]

Makes me happy to see where my money goes when I buy an ECU. Haltech is awesome.

[@JesusHernandez-xf9ik]

Will he film an outro? My bet is no😂

[@domoniquebrooks816]

Never has, never will.😂

[@OriginalMomo]

@@domoniquebrooks816damn, beat me to it 🤣😂🤣

[@lars3462]

he kinda did

[@paulhowlett6619]

Man for me it just loops😂

[@sxftcxre5614]

Wait.. yall haven’t been seeing his outros?! They’re in every video i thought you guys were trolling

[@andrewlangford88]

Nice to see some modern Australian manufacturing. Rare these days!

[@FURNACE_YGO]

I'm glad it is Aussie made just cool to watch that Australia is still making things of this quality that the world loves. ( Bring back Holden and Ford Australia )

[@SKI_NINE]

This is awesome to see being done by Haltech themselves... great video! Also gotta appreciate a good ol' factory tour (albeit a small one in the scheme of things)... for those interested in the fascinating world of pcb production take a look as some of strange parts and gamernexus' tours :)

[@Affinity111]

Watching this reminds me of the good old days of working at a semiconductor facility. I got to run these seriously intelligent machines and be a part of the production process of microscopic laser and fiber optic devices

[@xxvjvxx]

This is basically a small scale GPU factory. amazing

[@robertosanchez5548]

you push me to achieve better for myself in life and being an enthusiastic. Please continue growing and showing people how amazing your content is brother

[@gregkruse2389]

Haltech is an amazing company and a prime example of Australia's engineering excellence in the automotive industry.

[@stayntune]

🖤still running a E6K on my 13BT after 15yrs. Ready to retire it next season.

[@feenyx6394]

That has to be one of the coolest work barbecues ever, I'd be stoked to have a job at Haltech :P

[@LTLZLR]

I love watching your content bro. Keep it up. I did notice though how you pronounced Haltech, haha. So glad you have corrected that now that you’re on the better side of the world. 😜

[@reyalPRON]

real production has fab. respect for haltech hit a new level :)

[@richardschafer1911]

Us aussies are pretty proud of our haltech

[@ffeliziani]

We want the crossover with "Tuning fork" Scottie!

[@JonCherba]

I'm always amazed at how far technology has come

[@PWNAGE703]

Awesome engineering! Love this

[@bikergobrrr]

What a way to start a morning with some dahm

[@combatmatt97]

Fastest I've ever been to a video, now I get the pain of waiting for the next right away 🙃

[@SloppyMechanics]

thanks for this, i love this stuff

[@bboydrummer1]

Super cool. They definitely produce quality products. Thanks for the video.

[@SinfidelityMusic]

Wow! The qc is very reassuring. I’m super surprised that all that work is done in-house and not outsourced to China like a lost of electronics these days.

[@tedjones-ho2zk]

Poor QC, they are not following IPC standards on ESD

[@nodekapunk]

I really hope you have more haltech content. I’m trying to convert all my friends to use them… Especially since I bought a 2500 a month before they came out with their replacement. Now I need to sell it so I can upgrade. Haha

[@ethancadto5940]

Fun fact, The way they are doing it here is pretty much industry standard on the aerospace side to make sure circuit cards are built correctly and functioning properly before the rest of the larger assemblies are built up.

[@nobodyhome2318]

This video was so cool, I'm a fan of the company after watching!🎉

[@krnt13]

That was Beautiful!

[@evalpaslan8848]

That was amazing so proud🇦🇺

[@HoonTV]

Great video Rob

[@tgracing5532]

So happy you got out here in Oz to see what is here in the rotary scene but screwing I couldn't get down to WTAC to say hi.

[@mtech1961]

Great Video, really Hi-tech with 8 layer boards and SMT. Like Computer Mainboard technology but stronger and better tested by the look of it.

[@fishua5564]

That's baby making music right there!

[@Buck_Plankchest]

Thanks for the video, Rob. Fun nerding out on some interesting tech.

[@gw3extreme254]

Awwe cat daddy showing love for his cat children 😊

[@wthea7913]

This looks dreadfully familiar to my job in the powersports industry. Love to see it! :)

[@lasskinn474]

rob they did wave bath soldering etc long before you were in high school, you're not THAT old. and some oven stuff too. wave solder is why the boards from a certain era for high current stuff have that 'wrinkly' look to them, it was like running a wave of molten solder over the board.

[@leslienordman8718]

This episode is really different and really cool! Thanks for this. 🙂

[@can_with_beans]

"Step 1: Borrow a $2 Million Printer" Literal youtube meme of "to do this DIY, walk over to your $40,000 CNC machine"

[@Low760]

This is his sponsor haltech though. Not a KZbinr. Well Thier owners are American now.

[@goofygoodpasture8511]

someone in colorado has a "modernized" ecto-1based on a dodge magnum, and its really cool

[@classic_britain]

Each time I see you upload I hope it's the 12 rotor 😂

[@johnswan4551]

Haltech, the world didn't need to see the man using a cordless drill to screw in the PCB.

[@taway2]

Agree 😂 That production line scares me. Even the old one did but it looks slightly better now. I work in the industry and we have two high end production lines inhouse (not a big facility but it is property done since we have up to 30 years of warranty). Haltech seems to have no proper EPA with almost no ESD clothes or anything. No proper storage boxes (big no no to cardboard boxes beside a pick-n-place machine) and it looks very dirty. Our technicians would shut that place down after just one inspection 😅 Looks like they need some education and a field trip to a proper manufacturing facility. That resistor he is accepting with solder issues and too big solder pads (hardly an IPC size) hurts my eyes! I should probably check my own ECU... This is not something to show the world...

[@drgti16v]

Sydney is such an amazing city.

[@king0684]

That is beyond awesome!!!

[@r5obiwan]

Goddamnit I was watching s2 of top gear off of my sd card and now I see a rob dahm video, I guess I'll get back to top gear later

[@Bubbaj226]

Last time I was this early Rob eiffeled a Renesis

[@Senetus]

Kinda like a small-scale version of the Nokia mobile phone factory in the early 2000's, very cool stuff!

[@wfo8023]

Awesome video Rob. Thanks you for everything u do

[@CriticoolHit]

aaaaaaaaand that will be 5 grand thank you very much.

[@cn1364-w6c]

Hopefully Haltech pays you for your advertisements cause it's working 😂. I was going to go with a MaxxECU + PD20 combo but ended up going with a R5 + PD16 after one of your earlier videos (I think it was the 4rotor wiring video). Interesting to see some of the 'behind the scenes' of the company.

[@Low760]

They are one of his sponsors.

[@SIRICKO]

Damn Rob this was bad Ass bro I just got mt 1500 from Haltech. =) I will be getting A Nexus for my new build 1000hp 91 Honda Crx.

[@BenjaminEricksen]

Man!!! This so cool!!!!!!!

[@benjamindingledine6711]

Can’t wait to see what car you buy and bring home😂

[@WexWerxScott]

That's a neat process... But the single completed box filling the row... Ohhh muh ocd is happy

[@delusionalaar4031]

I would love to work for Haltech and build this stuff.

[@jagu420]

pretty much the same assembly line for most major standalone ecu brands.. the real gold is in the software.

[@R.F.McCoy200k]

I didn’t see a cold cycle or hot cycle test…I built chips for Cummins and ford and it was very similar expect we had a high temp coating that also acted as a sealant on every board and we would test every one before and after being put in a freezer for hours and a oven for hours then we would seal them in there cases

[@cds9000]

Love this

[@MrMorepower71]

That is really cool. Thanks.

[@johngato737]

The day I can afford my first Haltech will be like a child’s Christmas morning.

[@cjdavis3247]

Those pick and places are sick pieces of machinery, I assume those floors are ESD because I don’t see any gloves

[@gripplepete]

Next visit.. Pac Performance?? Great video Rob!

[@deltacharlieecho4732]

Man I can't wait to be able to afford a Haltech ECU for my m50 builds. Probably don't need it, but I have a feeling it will be a lot easier to do a compound m50b30 with a compound twin turbo setup than trying to do it without the processing power.

[@TroyMcKeown]

I've been waiting a long time to hear you correct yourself on the "Haltech" pronunciation!

[@hahaha12345678993]

first i ever saw anything haltech related was from mighty car mods with tuning fork

[@jaydenray2803]

Watching this felt a lot like watching Linus Tech Tips but for cars. A welcome surprise

[@kcheung99]

9:49 such a wholesome moment Joel: Yayy Rob: heheh

[@25aspooner]

So THAT is whats hidden inside my R5!!! 😁

[@sltillim]

I am considering buying a R5 right now. I am doing an engine swap and want to rewire my vintage car and current cabin controls (internal switches) to the PDM without using a new button board. Do I convert my old switches to CAN or even plug them in? trying to figure out these things.

[@daeng3]

I'm Waiting for 12Rotor Development🥳🥳

[@CarsNaddict]

I miss the old 1hr video Rob Dahm 😔

[@timmyanderson1576]

Aussie stuff is Aussie tough

[@grapes008]

If you want more indepth info on board assembly void* has a great video on raspberry pi manufacture that goes resonbly deep into the pick and place machines as well as soldering.

[@griptopia]

VERY COOL.. thanks for doing a hal visit..

[@LuxGamer16]

3d printed piece to hold the pcb down for live testing. Awesome to see my hobbie being used in so many fields.

[@nyvinchenz9430]

They have a good amount of inventory

[@lukebrennan5780]

Straya! Onya fellas!

[@RDSAlphard]

I was hoping Rob Dahm got a unique Nexus R5 where he helped build, haha.

[@easyBob100]

Kinda shocked you didn't have a JLCPCB sponsor for this one.

[@TheHighborn]

Rob if you want extra safety get a Cane Corso and an Irish Wolfhound. Everything will be beyond safe. Robber that comes in, will go out as dog feces

[@diysecuritygear9594]

I used to take pride offering my customers a bulletproof product. Absolutely the best. Stupidly sold my soul to investment capital and then it all went bell end within a year. Maybe you could use part W? It's .04 less expensive. Tragic downfall.

[@FenderRealm]

Come back soon Rob!

[@philscott7949]

3:34 That looks like a pack of 50 circuit boards.

[@iamarawn]

Would have been cool to put "inspected by Rob Dahm" on the box.

[@Epikchampo]

Just brought the s3 for my 13b turbo to run 8.50

[@xLaFitch]

rob, are you doing any meet and greets while you are in austrlia? I would love to meet you!