Secure Development Practices Assessment Certification (SD-PAC)

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PROJECT
Motorcycle Ignition Control System (ICS) Reverse Engineering

CUSTOMER CONCERNS
The motorcycle’s ignition control system (ICS) governs the spark timing to ignite the engine’s fuel-air mixture. The client needed to understand if the system could be reverse-engineered to tweak the performance of the motorcycle, such as increasing horsepower by adjusting spark timing or altering the rev limits.

THE MISSION: WHY WE HACKED IT
The ignition control system on this motorcycle was being investigated for potential performance tuning. The system was embedded within a sealed box and controlled the timing of the ignition sparks via a microcontroller. The client wanted to reverse engineer the system to modify the engine’s performance. The goal was to learn more about the ICS and determine if it could be reprogrammed to boost performance without compromising reliability.

• Hardware Deconstruction: Attempted to physically access and probe the circuit board within the sealed ignition control system to understand how it operated.
• Microcontroller Identification: Identified the microcontroller governing the system, despite challenges caused by the protective sealing, and searched for debugging or reprogramming interfaces.

• Sealant Protection Mechanism: The system was heavily sealed with materials designed to deter reverse engineering, which led to some damage when trying to access the board.
• No Debug Interface: Despite thorough testing of potential interfaces, there was no straightforward method to reprogram the microcontroller or extract the firmware.
• Limited Firmware Accessibility: The microcontroller utilized mask ROM, meaning the firmware was hardcoded and could not be extracted without advanced techniques like decapping.

• Pivot the approach to Black Box Testing: By simulating the inputs and measuring the outputs (e.g., camshaft position and throttle), the client successfully inferred the ignition timing algorithms.
• Build a Custom Simulator: The client created a custom microcontroller system to mimic the ICS behavior and explore performance tuning possibilities.

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PROJECT
Sprinkler Controller with BLE Support and Mobile Apps

CUSTOMER CONCERNS
With the addition of Bluetooth Low Energy (BLE) support, the client’s updated controllers were designed to allow users to control the system remotely via mobile applications. The client needed to ensure that this new connectivity didn’t introduce vulnerabilities, which could potentially expose customer devices to unauthorized access.

THE MISSION: WHY WE HACKED IT
The client was integrating BLE into their next-generation IoT sprinkler controller. BLE is a common technology in IoT devices, but it’s also a frequent target for hackers due to its security misconfigurations. The client needed assurance that the new connectivity didn’t open up paths for attackers to compromise devices, manipulate sprinkler settings, or gain unauthorized access to user networks. Our goal was to pinpoint any security flaws early, ensuring that customers’ homes and gardens weren’t at risk from cyber threats.

• OWASP Top 10 for Mobile Applications: Assessed the mobile app for vulnerabilities like insecure data storage, insufficient transport layer protection, and improper authentication.
• IoT Testing for BLE Configuration: Examined how BLE was implemented and configured to ensure there were no common misconfigurations like lack of authentication or unencrypted data transmission.

• Design Flaws in the BLE Pairing Process: Weak pairing mechanisms made it easier for potential attackers to eavesdrop or interfere.
• Vulnerabilities in Mobile App Data Handling: Sensitive data was being stored without adequate encryption, making it possible for an attacker with device access to extract and misuse it.
• Exposed Device Commands: Several BLE commands used to control the sprinkler settings were not properly secured, leaving room for unauthorized manipulation.

• Secure the BLE pairing process, ensuring that only legitimate users could control the device.
• Implement secure storage and transmission methods for sensitive information within the mobile apps.
• Lock down device commands, reducing the likelihood of malicious tampering.

As a result, the client’s BLE-supported sprinkler controllers were not only more secure, but they also provided peace of mind to end-users, who could trust that their smart systems were robust against potential cyber threats. This proactive security testing allowed the client to go to market with confidence, turning a potential risk into a competitive advantage.