Build: Spark Plug Tester

Beware of 25,000 volts!

A few years back, I had the incredible opportunity to take on a commissioned project for a dear friend of mine. The task at hand? Building a spark plug tester from scratch. It was an exciting challenge that allowed me to put my skills to the test and dive into the world of automotive engineering. Today, I want to share with you the story of how this project came to be and the journey I embarked on to bring it to life. After much delay and anticipation, I am thrilled to finally share my latest work with all of you. Life has a funny way of throwing curveballs, and unfortunately, publishing this piece took longer than expected. But hey, better late than never, right? 

So, without further ado, here it is! Pouring my heart and soul into this project has been an incredible journey. From the initial spark of inspiration to countless hours of research and writing, every step of the process has been a labor of love. Ah, let me tell you about the exhilarating journey I embarked on with this project. 

Example of a spark plug cable replacement part.

Courtesy photo from ProtonPeroduaParts.com.my

It wasn't just about tinkering with electronics; oh no, it was so much more than that. The true thrill lay in the art of constructing the very foundation for the spark plug. When it comes to purchasing spark plug cables, your best bet is to head over to your local auto parts shop. There, you'll find a variety of options that include both the cable and ignition coil insert. However, it's important to note that some of these cables may be on the flimsier side. 

Unfortunately, they may not come with a latch or any mechanism to securely attach them to the construction box. So, I made the bold decision to embark on a thrilling adventure - building my very own creation from scratch. In my latest project, I decided to delve into the world of high-voltage generators. To achieve this, I opted for an old flyback transformer salvaged from a CRT TV.  I couldn't resist the allure of repurposing this vintage piece of technology to power my circuit. 

As you scroll through these images, you'll witness the transformation from mere blueprints. I am thrilled to share with you a project that has brought me immense joy and satisfaction. I sincerely hope that you will find it equally enjoyable, and I eagerly await your feedback and any similar projects you may have embarked upon. 

Always test your circuit first on a breadboard

I built the PCB using the toner transfer
technique for this project. Got a pretty good result.

I used the old CRT flyback transformer for this
project and the 2N3055 transistor for the driver

This is what the inside looks like. The left side is the high-voltage
circuit meanwhile the right side is the low-voltage supply

A simple construction of the spark plug holder

The final construction with the protective plastic cover

Close up photo