Project-M45 super charger (developments)

[jkarran]

JK i dont blame you one bit!! whish i could be out and about driving mine N/A or S/C

I took it to work today, it's bloody hard work and scarey to drive but you can't beat the sunshine on your face. Plus people smile and wave... that doesn't happen in the 540

jk

[appletree]

Why is i hard work to drive? i can imagine it must be pritty scarey with no weight and plenty of power.

[jkarran]

It just darts about all over the place and you're constantly on guard being at headlight/truck-wheel level It's also pretty tough on your neck and back under acceleration and over bumps

jk

[appletree]

Done quite abit more to the project now, got all the pipe work done for the charge cooler, bought and mounted a pump made some connections for it, made a bracket to support the throttle body as it had a little vibration on the over run, and i'am no starting work on the laminovas!

Also ordered and recieved my Emerald m3d engine managent and sensors, made a wiring diagram for it and have sent it back to them to see if they think it looks correct.

Its also booked in for a mapping session at Emerald on the 20th of june so i've got abit of a rush on to get everything togeather in time!

i'll post some pics up of the progress once i get a chance

[stuartgallafant]

sounds good matt

how come you went for emerald and not MS?

[appletree]

Ive like the emerald stuff and dave walkers/emerald have helped me out along the way with some of the problems ive had, seamed abit rude to ask all mthe questions and then buy something else.

were you been stu, havn't seen you posting for abit??

[appletree]

heres aload more pics of what ive been up to recently


firstly heres a pic of a stainless steel cover i made to cover all the injectors and the pipe work for my charge cooler, it will also cover the temp sensor when i mount it and is the bracket for the adj fuel reg.





This is the mount to stop the throttle body from vibrating which it did alittle as there wasnt a support before.



heres the place were my bailey dump valve will go, this valve will open when the engines at idle allowing the supercharger to "freewheel" and make its so its not sucking or pushing against anything as the air will recirculate.



My shiney new emerald ecu with MAP and temp sensors.


This forge dump valve is going tobe my back fire valve, this will just mount on to the manifold and protect the charger aginst a back fire. it will lift and vent to atmosphere it there a is a backfire in the inlet manifold. some american cars use a thin piece of metal in the side of the manifold that will fail under high pressure and relise the pressure in the manifold however seen as my car wount be running that higher boost level i think this valve should flow enough if the situation arises.



Finaly some pics of me making the laminovas!!!! 50 slots either side of the middle and 8mins to cut a slot! yes a very long time!!! thank god our lathe has power feed.

the fines ended up at 1.8mm gaps and 1.8mm fins i try'd doing them at .8mm on a test piece but it took forever and did'nt machine nice atall so in the end i went for the bigger ones, the other problem is that the smaller the fins the smaller the surface area and then you start to get pressure drop.

[stuartgallafant]

things are really comin on now matt, everything is looking great.

how much did the emerald set you back?

[stonesie]

Looks 'farely' lethal that i like it


This whole thing looks awesom man and i can't wait to see how much power and torque this thing makes

[gareth]

the laminovas look cool! i bet deburring took a while too!

[appletree]

Emerald was £680 all in, inc VAT a MAP sensor at £70 a Temp sensor at £12, postage ect ect thats with a base map, ive still got to go and get it mapped which is on the 20th of june and IIRC was £270 for ther session which includes the 3 maps that you can switch on the move via the dash switch, (unleaded, super unleaded, eco or more than lightly RACE )

up until i bought the emerald the engine mods have only cost around £500 as all the materials were free an ive done all the labour apart from the welding which a mate did for free as i did some machining work for a project he had. the super charger was £180 and the ive just bought the hoses, clips, wires, pumps, gauges......

as for the machining set up i have to agree it does look pritty leathel but its extremely soild and did'nt chatter or rub atall

deburring, PPPPFFFF. lol its cut that well that there isnt any burrs atall!!! i was expecting to spend hours with a file slowly filing each fin but it look pritty smooth to me, might give them a little tickel anyway though

cheers for the nice comments lads

[Turbo-Brown]

Wow, that cooler looks wicked! How'd you get the hole all the way through it though? Bloody long drill bit or something?

So did you get the K3 ECU? Gonna have to send mine off to be updated while the car's off the road. Would be nice to have the self mapping feature

[appletree]

The hole was dirlled by a local engineenering company with a very long drill drilled from either side so it didnt "wonder" as my dads lathe wasnt big enough, £40 to have two done!! and if you think thats expensive it should have been £80 but he knows me and me dad through our work places and did it cheaper.

there will be two of these coolers one on top of the other with a ally plate across the front with a two slot in so that the air hits the middle of the cooler splits up/dwn and then travels along the top/bottom of the coolers to give the longest contact time, imagin the path of the air going over the tip of a plane wing. Also as the coolers are also quite large there a nice mass to soak up the heat.

i asked for the latest veriant of there ecu which is the K3.

Nice to hear of some one else running emerald! What type of state was the car i when you went for mapping? all wired up, could idle, partly drivable??

i'am abit unsure of setting up the cold idle side of things

[stuartgallafant]

wow, you got all this for a real good price then matt! you're lucky you can fabricate all your own stuff!!

[appletree]

Ya if i had had to by the materials and pay for the labour it would have been a huge bill and probably taken ages to do as ive been working on it most dinners at work and then doing the machining jobs when i get back from the girlfreinds at night.

all good fun

[jkarran]

Good progress Matt, this is going to look absolutely awesome when it's all fitted and finished. Should go well too

Cheers for the progress report, I'll keep checking back in to see how you're getting on. Mine's back on the road NA for the summer (I couldn't face the re-wiring with the sun shining outside ) and the E30 is on axel stands and has been for months. Need to get that moving soon or my mother will scrap it while I'm not around!

jk

[appletree]

Quick up date on what ive been doing!

i have machined the second laminvova 24 hours in total to machine all those fins in both cores!

ive drilled both ends of the manifold so the core ends can poke through.

machined two plates to make the sealing arangement for the end of the laminovas.

and chopped the middle box out of a spare centre section.

As bought from JC-BM, did any one realise this bit is also stainless!!!



All tacked up after ages groveling about under the car on axel stands trying to line it all up.



All blazed up with a boss for a wide band.





Not sure wether to leave it with the heat marks on it or polish it all up shiney shiney?? shame no one will actually see it

[oze30]

Quick up date on what ive been doing!

i have machined the second laminvova 24 hours in total to machine all those fins in both cores!

ive drilled both ends of the manifold so the core ends can poke through.

machined two plates to make the sealing arangement for the end of the laminovas.

and chopped the middle box out of a spare centre section.

As bought from JC-BM, did any one realise this bit is also stainless!!!



All tacked up after ages groveling about under the car on axel stands trying to line it all up.



All blazed up with a boss for a wide band.





Not sure wether to leave it with the heat marks on it or polish it all up shiney shiney?? shame no one will actually see it

If they do see it, then you've prolly done something VERY bad!! Lets hope the only way ppl see it is from under a ramp!

Good luck and congrats on the progress!

[stonesie]

Totally off topic BUT that looks a nice callender


Seriously though this whole thing looks awesom, bet you can't wait to get it all mapped up and back in use

[appletree]

stonesie- yes it is mate!

well spotted

[appletree]

Some more progress

Made the plate that the laminovas will fit in, the i dea is that the plate will make the air traval around the core of the laminova so it has the longest contact time possible.

Heres the plate bent with the holes drilled at either end of the slots ready for the centre of the slots to be ground out and then the edges milled.




The plate with the slots machined in


Both laminova cores finaly machined up, just the ends to turn down to suit the end plates on the manifold

They will eventualy have 10mm push fit air line connections on the end, the small hose tails pictured were just to check they lined up with the holes in the ends of the manifold




The two laminovas sat in the plate


The long edge on the plate will be bent back at 45 degrees to form a seal against the bottom of the manifold so the air can only go through the laminova cores

[gareth]

that looks nice. is it not a bit restrictive though?

if the laminova cores are touching, could you do away with the horisontal centre sections?

just a thought...

[appletree]

i've worked everything out not to be restrictive, the supercharger out let is 37sqcm the gaps in the fins give 64+ sqcm and the slots in the plates gives 58sqcm so the cores souldn't be restrictive i had origionaly thought about having no plate but then the air could just rush through the centre and bottom and would not have a very long contact time with the core to transfer heat, this way the cores shouldn't be restrictive but should make a cool charge.

[gareth]

i stand corrected.

does turbulence not have an effect?...



i'll go now, i'm being a pain!!!!

[CraigG]

will the boxed in-ness of the cores not mean a high pressure area in there, ie the air cant flow properly from one side to the other backing it up, meaning it will go elsewhere instead. same problems are had when an intercooler is backed directly onto a radiator. lack of airflow means the air that is there is under a higher pressure, which stops more air from coming in. and is diverted away from the core.

[CraigG]

you mention you boxed it in for contact time also, this will have a detremental effect, if the air is hanging about there for a long period of time, as i said above it will create a high pressure zone, stopping any more air coming in, its not about contact time, but volume of air passing over the core

[appletree]

The air can only go through the cores as they sit right in the centre of the manifold and are sealed against the top, bottom and sides of the manifold so there wont be a problem with the air being able to "go some were else" or bypass it, as for the high pressure zone building up in front of the cores i can see what you mean, the idea is that as the slots and gaps are abit less than twice the size of the S/C out let there shouldn't be a build up due to a restricive air flow path.

Another thing to consider is that the engine will be using air on the other side of the cores so could create a lower pressure zone which will also help suck the air through.

The laminovas will also help to distribute the air equaly to all 4 cyclinders rather than the two opposite the S/C port.

The thing with heat transfer is that you need the maximum cooling surface area to disipate the heat, the idea behind the plate is to maximise the surface area avalible for cooling, yes this will offer an eliment of restriction but the cross sectional area of the gaps in the fins and the slots should allow suficient flow with out too much back pressure .

Additionally the air flow in CFM is very low at small throttle openings, real volumes only start to occour when on boost at WOT.

In the ideal world the intercooler would offer no restriction in practice the will always be some restriction in something which has to fit in the inlet manifold.

you could go with no intercooling in the manifold an thus no restriction but as i have found the charge temp is a little high and the volumetric efficiency drops off and thus the avalible power output, its swings and round abouts am going to have a go on the swings

[CraigG]

i suppose you can always rip it apart and remove the restrictive plate :p

either way its going to do its job, the air is going to pass over the fins, and the water will cool the fins. just one way the air/engine/charger has to work more getting the air to, and then from, the fins. and the other, it just flows through with the only restriction being the fact that there are a bunch of ice cold fins between the air and the cylinders :p

[appletree]

Heres the idea ive been copying if you want to look and see how the pros do it.

http://www.alertmotorsport.com/intercoolers.htm

Another intresting project with laminova cores.

http://www.bmwpower.lv/my.php?op=galler ... e&pid=1927

[stonesie]

Some good pics in that 2nd link mate..........




at least theyre useful

[appletree]

well ive put it all back together with the laminova cooling and after a slight problem with it seaming to miss and drive shit my dad noticed that i'd left the AFM unplugged

with the meter plugged in at all ran fine and realy pulled well, it realy sat the back end down in every gear.

also the laminovas seam to be a big success with the supercharger being nearly to hot to touch and the manifold just to say warm. The water in the tank had had the chill taken off it after quite along quick run so it a seems to be working alot better with the laminovas in also a much better idle and no backfiring at low RPM.

As for what PSI it was running ive swopped the shite "tims" gauge for a proper digital pressure measuring meter my dad bought a while back and it was running 9.89psi boost max with no pinking.

Its also quite a hot humid day here which makes the above even better. 22c and 65% humidity

[stuartgallafant]

nice one matt, sounds good! i bet you cant wait to get on a rolling road!!

when is the emerald going in?

[appletree]

i'am just waiting for karl at emerald to check through the wiring diagrams i made up to make sure they all look good. they should have been here today so as soon as they are here i will be making up the addaptor plug and fitting it.

getting mapped on the 20th so times running out!

[jkarran]

Awesome Matt

Sounds like it's working really well. Is that 10 Psi on the standard compression engine?

jk

[appletree]

Yea the 10psi was the peak value @6500rpm on my dads wika digital pressure calibration unit, 7ish psi any time no sign of pinking, probably over fueling @ 3.75-4bar but dave walker said witht the injectors i have in now running a @4bar there will be enough fuel for 200BHP with them running at 75-80%

the engine now has my custom streight through centre section to which will be causing less back pressure to, it is how every pritty quite infact i would say its quiter with the streight throuh than with the standard section.the tones changed to it now more metalic.