April 29, 2011

Plasma Ignition Setup on a Ford Mustang 3.8L V6

Filed under: Fuel Economy,Horsepower,Plasma Ignition Install — admin @ 10:08 pm

We have got a lot of requests for installation pictures and how to go about installing a plasma ignition module in a step by step fashion. So here it is. The vehicle we picked is probably among the harder ones to install on, because it is a waste spark ignition system.

Step 1: Figure out the Polarity of the coil pack (Skip this step if you don’t have a Wastespark setup)

Waste Spark coils fire two simultaneous sparks in two cylinders only one of which is in the power stroke (the other spark is ‘wasted’ as it is in the exhaust stroke). One of the sparks is a ‘positive spark’ (because it jumps from the spark plug center electrode to ground) and the other is a negative spark (which jumps from ground to the spark plug center electrode). I decided to use a High Voltage diode I had lying around, and oriented it so that it would only allow the ‘positive’ spark to go through, and I fit a spark plug holder tip to one end.

After this I pulled out Plug wire # 3 from the plug, inserted the free diode into the boot, and put a spark tested to the other end after grounding it to the chassis. I turned the engine, and I noticed that the spark happened – so wire #3 was a positive polarity. Similarly I determined that cylinders 1, 2, 3 fired positive sparks and cylinders 4, 5, 6 fired negative sparks.

Step 2: Attach the coil / distributor end boots to the supplied plasma ignition cables

The supplied RF suppression dual conductor plasma cables come unterminated at the coil end in 3ft lengths. Now that we know which towers on the coil packs the positive and negative cables go, its time to appropriately choose the lengths for these wires and attach the coil end boot assembly.

Step 3: ‘Buss’ up the high current plasma leads from the supplied plasma ignition cables

The 3 positive cable high current leads are all joined together below using a heavy duty crimp connector. Do the same for the 3 negative cable leads

Step 4: Swap out your spark plugs to non-resistor spark plugs

We went with the Yttrium A3c Brisk spark plugs. The Yttrium alloy does wonders when it comes to withstanding the punishment of the plasma discharges.


Step 5: Prep and mount the SparkAmp Plasma Ignition Module

Things to keep in mind here:

– The lengths of the supplied Plasma Bus Wire (Yellow) and whether it can reach from where you bussed the high current cables to the output of the sparkamp box.

– An appropriate spot to get a key on power source. Here the pictures show that we take it from the power going into the coil pack itseld, but we later changed this to use the power from the coil pack to turn on a relay which controlled power directly from the battery. Remember that the thicker the power supply wires and better the connection, the better the plasma unit is going to like it.


– We want to ground the Plasma unit to the best ground available on the engine block itself. The idea behind this is to limit the length of the circuit comprising of the SparkAmp module, the wires, the spark plugs, and the return ground wire. So you don’t want the signal to circle the rest of your chassis before ending up back into the sparkamp unit.

Step 6: Hook up the plasma bus wires

Measure up the lengths required to run from the bussed up plasma cables all the way to the plasma unit. Then strip away a little bit of the wire and hook it up to the other end of the crimp connector making a secure connection.

Finally everything is hooked up! Just to test everything is in order, pull out one of the plugs and fire them so you can see the plasma spark. Boy what a spark!