Project-M45 super charger (developments)

[appletree]

just a few more pics of how its all looking at the moment.

its nearly as it will be when its finished apart from afew hoses and pipes.

[gareth]

i've said it before and i'll say it again.... sweeeeeeeeeeeeeeeeeeeeeet!

[Andy335Touring]

i've said it before and i'll say it again.... sweeeeeeeeeeeeeeeeeeeeeet!

+1

and a very tidy looking install

[max318i]

Absolutely epic project, have been reading it since the beginning, every time there is an update i'm happy !

Where does the water that is ciculating in the cores come from?
Again brilliant work and give us some more videos soon please.

Max

[ShepsEvo3]

That S/C certainly dominates that engine bay! Looks cool, but I think you'll have a job keeping that away from the insurance company!

[appletree]

No its all going to be declared!!

£2300 for a year fully comp ( with no years no claims as they would not let me carry my 3 years NCB 1 was a bounus only 2 so ive started a second policy so i can have my daily driver insured for £500 and the bmw seperate)

i am realy pissed off because before i started the project i rang up and got a quote for £1400 , to see if the project would be viable, the same price as i pay at the moment N/A but by the time i insured it i would have another 1 NCB so in effect the price would stay the same but i would have another years NCB .

When i rang up a month ago they gave me the old were sorry someone must have made amistake........

you have to remember that i am only 19 aswell!!

as for the water, the water is held in the large windscreen washer resivour and the small resivour does the windscreen now ( rather than the headlights/intensive wash). the water leaves the res and is pumped throught the laminova cores and then through a front mouted oil cooler and back to the res meaning that the heat it gained in the cores is then lost to the atmosphere as air passes throught the oil cooler.

[Andy335Touring]

Have you tried HIC for your insurance ?

[gareth]

bad news mate

my insurance company (adrian flux) are cheaper on my M30 335i than a standard 325i that's ALL mods declared. may be worth a go? that said, i've got 9 years on you how does £330 fully comp with protected no claims sound

[d6dph]

Absolutely in awe of this, Fantastic work.

[appletree]

bad news mate

my insurance company (adrian flux) are cheaper on my M30 335i than a standard 325i that's ALL mods declared. may be worth a go? that said, i've got 9 years on you how does £330 fully comp with protected no claims sound

Oiii dont rub it in!!! i've tryd everywere loads of people start laughin when you say its supercharged and your 19!!

infact by hte end of the day and the number of times i gave out
my name, address, job only to be refused i started to say steight off before you take all my info whats the chances of you insuring a 19 year old with a superchargerd BMW....... no dint think so

i seriously looked at swopping to a e36 M3 as with my punto insurance and my BMW coming to nearly £3000 i thought i wouldn't be to far off 300bhp m3 but the ceapest quote was £3200 which is to much even for me and i dont think i would be able to sell the project after all the work iv'e put in.

[E30Mark]

Looking lovely, You should be proud of your efforts there! Hope the remapping goes well.

[CraigG]

apple tree, HIC do a pay monthly insurance thing, i was speaking to a 19y/o at a car show the other week, he just biult himself a 2.0l 16v corsa. was trying to get insurance, HIC wanted 2500quid for a years policy, he asked if they do a pay as you go thing, they said yes, and it was only 160quid a month.... and there was no limit to the ammount of months back to back he could have this so hes getting a years insurance for 1800 instead of 2500 :p

might be something to enquire about, obviously this wont biuld you no claims, but if you have another car doing that, then it dont matter

[jkarran]

Ouch! That insurance bill has gotta hurt.

It's looking sweet though, you must be well proud of that

Adrian Flux do my Striker for about 300 notes fully comp and when I inquired about mods (what a daft concept on a kitcar) they said it would be roughly +1% cost for +1% power. Seemed like a good reason to aim for low end torque

jk

[dodgem]

Yay! I've finally finished reading this project from start to finish. I am so impressed by all the work and research that has gone into this, and especially by the fact that it's fitted to an M42 (since i have a 318iS )

I'm totally lost when it comes to the theory of turbos or superchargers, or at least i was totally lost - now i feel i have a faint grasp on what goes on, so thanks for educating me

The only part i feel i can give any input on is the laminovas - which are looking very cool!!

You mentioned that the SC output area is 37sqcm, the fin gaps are 64+sqcm, and the slots are 58sqcm. But the fins sit up against the gaps, and are 1.8mm fins / 1.8mm gaps (ie. 50/50 fin/gap) so forget the 64sqcm figure, the actual gap for the air to flow is half the slot area, 29sqcm. Add to that the fact that one big gap flows better than lots of small gaps, and i think you are adding in a fair bit of restriction there.

CraigG's point about volume flow being more important than contact time is only valid when using the airflow to cool the liquid in the laminova (ie temp change of the air is unimportant), but in this case you are cooling the air, therefore high volume flow in the cooling liquid is important and air contact time is important.

Personally, i would increase the area of the slots - a blocked area over the point the laminovas meet each other and the top and bottom edges is good since it prevents air flowing through without "touching" the fins at all, but it doesn't matter that the air flows near the end of the fins - infact it's probably better since you are setting up a temperature gradient in the direction of fintip -> core, rather than fintip <- midfin -> core (hope that makes sense). Also giving more flow area will decrease the speed the air has to flow over the laminovas, increase contact time, and give better cooling.

Sorry if i'm teaching my grandmother to suck eggs here, but thought it might help - as i said, this is the ONLY part of the project i actually have any knowledge of so if it doesn't fit with the rest of SC theory then ignore me and call me a muppet

Well done anyway, and errrr, if you feel the need to repeat the project for some reason, i have a willing engine

Simon

[appletree]

Mats Dad here
Thanks for the nice comments and the support dodgem.
I suppose the "bit" thats in question is the aperture area, each oval is 15mm wide 50 fins + 50 gaps long ie 100x1.8mm. Therefore csa = 180mm x 15mm = 2700. 2700sq mm div 100 = 27sq cm now div by 2 (fin/gap) = 13.5sq cm multiply by number of slots 4 equals 54 sq cm total CSA facing the flow. Do we now concur or am I missing somthing regarding Fin theory I think we are in step with most of the rest, there are lots of other things that can/could have been done, slots along the length to act as a thermal block front to rear of coolers, to mention just one. There are inevitably many compromises but even so the coolers seem to work very well. Manifold metal temperature has dropped from 70 deg c to virtualy ambient. Development has had to stop as the booked RR sesion is very close, we obviously need to determine the diff pressure across the laminovas, however much of the time it will be minimal (small throttle openings), the problem will be worst at full boost. If the diff is too great we may have to revisit, after all what will Matt do if its perfect straight out of the "Box" fit a V12?

[dodgem]

From those calcs you're absolutely right Matt's dad

I just looked at the figure that i thought was the aperture csa (58sqcm i think i quoted) and assumed that was before taking into account the fin/gap areas

Nevermind my ramblings then, it's a good job you two have thought this through longer than i have! As you say, there are more things you could do to improve the laminova, but if it's cooling so well already then why spend the time doing it?... I guess it's my mindset, i tend to overengineer anything i get into, sometimes at the cost of not finishing it!

Anyway, good luck with the RR in a few days time, i look forward to reading the finishing entries of this project. And as promised, you may call me a muppet - i'll be round my gran's flat giving her a few tips on eggs

[appletree]

We're founder members of the over engineering club lol

[stuartgallafant]

matt, this truely is legendary mate, well done

[Demlotcrew]

Wow this looks soooooooooo good!

Cant wait to see it at a meet

[Apal]

Again well done - excelent job.

I know full well what this kind of project entials having fitted an Eaton M90 to a 2.7Ltr E30. Lots of time and lots of head-scratching, but worth it when it fires up for the first time.

[Gortour]

E30 M3 is around 190 - 230bhp dependant on model. To get the 300bhp, you would probably need the 6 cylinders.

300bhp on a 318iS would probably be reliable for about 30 seconds... if that.

[stonesie]

Its an awesom project is this, i wish i had the skill and the equipment to do such a thing myself


It must ba agonising being so close to completion

[maxfield]

E30 M3 is around 190 - 230bhp dependant on model. To get the 300bhp, you would probably need the 6 cylinders.

300bhp on a 318iS would probably be reliable for about 30 seconds... if that.

I've seen S14s running well over 900 with a turbo.

There is a 500hp E36 318is in this months PBMW.

A great project

[Gortour]

I've seen S14s running well over 900 with a turbo.

There is a 500hp E36 318is in this months PBMW.

A great project

These are modified M3s though Max, I was under the impression that this was being compared with 'standard' M3s...
Obviously MUCH more is available from an M3 if the money and effort that has been put into this iS...

[appletree]

200bhp and loads of torque will do for me.

i've seen the 500bhp one in thes months PBMW mag and 500bhp would be nice but how long will it las for?? also i havent done any internal mods to the engine, its running just as it left bmw. the reason for not aiming for 500bhp, is i want somthing thats reliable, insurable and tha tdoesnt cost the earth to build, as i said this has cost me less than £1500 for the engine mods and i dont think to would be able to get 500bhp on that budget.

as gortor said if you want silly power the best thing to do is to use a 6 cylinder then you can go down the pub and shout about how many bhps your car makes with a 3.8 m5 lump turbo'd to 1200bhp but weres the point? can you actualy use all that power?

Danny can you post alink to the e36 car please wound'nt mide having a look at that is it turbod or supercharged? there do seam to be more high bhp turbo'd cars rather than superchaged ones.

who knows i might compound charge it yet




Ive been busy again got the wiring diagrams from emerald on wednesday and they are so good!!! infact i built the hole adaptor plug today and the rest of the loom and then used a metre to check all the wire went to the right place. only a few more odds and sods to do now but its suprising how much time they all take up.

picking up my mates car trailer on mon/tues day redy to travel down tuesday night in readyness for an early start wednesday.

dont worry i will post the results as soon as i get back and a dyno sheet. might even ask dave if i can borrow his PC

[Dave_M3]

Be interesting to see how my Turbo plan works out compared to this. Are you doing everything yourself bar the Re-mapping stuff etc. Im hopefully building everything myself including the manifolds since I love the satisfaction you get when it all works out because you made it work

[appletree]

Yes mate i have done everything my self bar the remaping and the welding as i havent got enough skill with a tig set yet, but hopefully someday i will have

when you do you turbo set up make sure you do lots of right ups and pics as and am surer others would love to see the pics.

as for the turbo route i think you will be able to get quite alot more power out of the little M42 than i have.

there are alot more people turboing the IS now to so theres abit more info on the subject.

your probably not this far on yet but iff you decide to run the emerald ECU like i have, i have all the wiring info to make an adaptor plug toplug streaight in to the OEM loom if its any use to you PM and once ive typed it all up all send it to you.

[shalmaneser]

Just a quick 'WOW'

I'm about to buy an IS as a second 'fun' car, this is such an inspiration!

Well done that man!!!

[SHAKEELE30]

Just wanted to say, a big well done on this project your doing, looks amazing, and especially when you've done most of it yourself..

Well done

[appletree]

traveled down to dave wlakers work shop tuesday so we could have a good dayat the rollers wednesday.

the day started ok with us ariving early doors to get ready and unload the car.

The last time you'll probably see my car behind a volvo



Had a slight problem when the charge cooler pump dying near the start of the session, lookaly though it was only the thermal cut out switch and it reset but we had to rig up cooling fan to kep the pump cool.



anyway we got on to the proper maping and had to drop the cooling water twice to keep it cool mainly as my charger cooler radiator was'nt big enough to disapate the heat, so theres a little room for improvement there, theres also a little slack on the belt on the over run which is causing a bit of vibration so i'am going to put a second tensioner on the under side to get rid of the viabration.

a pic of it all on the rollers



I have a few vids but there only on the rollers and i cant be bothered to post them at the minute.

but heres the DYNO sheet

peak BHP- 205.5 (Red)
peak torque- 176.8 (blue)

[randomdave325]

loving the torque! i bet it sounds ace
top car. well done

[CaesarBob]

Fantastic result!!

Looks like you got the numbers you were hoping for!

[Ant]

Superb results from an excellent project, well done Matt ( and Matts Dad )

loving that torque "curve" and nice linear delivery on the HP

[ShepsEvo3]

Good results, 6.5 psi at 2500 RPM is nice and nice smooth delivery. Nice flat torque curve too.

This is with standard internals?

[d6dph]

Result! Very pleased for you.