Project-M45 super charger (developments)

[stuartgallafant]

this is true. although for the money, i think its worth a play!

let us know how you get on

[Francisco]

www.downingatlanta.com

[stuartgallafant]

www.downingatlanta.com

[jkarran]

No serious work tonight... my friends just got a new dog, playing with that was way more tempting than getting covered in stinking resin

I did however want to do something so instead of getting stuck into another messy or tricky job I decided to have some fun. The car needed a grille and I'd been planning to do it for ages.



It's soft soldered nickel bronze brazing rod, it'll be getting a coat of gloss black as it's far too at the moment!

Serious work re-commences when I get the stock for my power take off pully.

jk

[jkarran]

i'm very impressed with the work involved and feel an almost uncontrollable urge to fit a jag blower to my M30 and finish it off with some nice homemade carbon ducting!!!

Do it! That would be a serious motor
jk

[appletree]

got a bit further with the project over the weekend,

firstly my little pump for the charger cooling. isnt it nice!!! very highly spec'd for the job and its a VAG one so its good quality,its a impellor type with neyoprene internals so it can withstand heat and coolent, aparently they are used on the MR2 trubos to.



Stripped the engine down some more to

marked up, took loads of pics for referance points



cams and tappets out


you can still see the orinal honing marks in the bores


the head, looks like its been running a little rich and spark plugs haven't been changed for abit



The sump just as it came off, i havent wiped it or anything just let the oil run out.

[Andy335Touring]

How clean is that sump, like new !

I like the dinky pump too, before i read the text i thought it was an ICV

[gareth]

that looks seriously well looked after! nice one!

[jkarran]

Mmmm clean. My 300mile old R1 sump was dirtier than that Looks like you have a good base to build on there.

What a funny design for the cam and timing chain cover, guess it works though, just looks odd. Was the pump an Ebay bargain?

jk

[stuartgallafant]

what is that pump gonna do then matt?

[d6dph]

I'm guessing it's a pump for the coolant for the chargecooler system. pumps it round so it circulates through the rad.

[appletree]

the pump was £55 from ebay (the_pump_company) and is going to be for pumping the charger cooler water through a oil cooler in the front skirt and then through the laminova tubes (cooling rod things) and then back in to a screen wash resivour, i'am gonna try and use the tin tank one from a car with the headlight wash kit so i can keep it looking factory.

any one got one of the twin tank??

[gareth]

i have

[appletree]

And is it for sale??? PM me!!!!

or was you just taking the piss

[jkarran]

I got a couple more jobs started/done this evening:

Relocating the shifter bellcrank out of the way of the SC inlet. It's an item I was never very happy with being heavy, ugly and adding play into the linkage. The new one will be similar but neater, it looks like it will fit... just. Interestingly the ballraces in the bellcrank were very rough so they'll probably be binned in favour of a simple greased bush.

Also done tonight I converted a spare R1 rad fan from suck to blow opperation, I could have just reversed the motor but if it's going to draw all that current the blades might as well work as efficiently as possible. That'll keep intercooler efficiency up at low speed for big standing starts No such issues with a charge cooler

jk

[stuartgallafant]

is there no way of using a regular type intercooler instead of the laminova application?

[appletree]

i could do if i relocated the charger to say where the alternator is and then pipe it in that way but it would still be difficult with all the pipe work going from one side of tghe engine bay to the other and then back again past all the heat from the back of the rad.

doing it like i have means i dont have to play around making brackets and mounts to relocate the S/C and the Alternator i was thinking of running no I/C like the Downingatlanta kit but then when some one put the link to the laminiova site it made sence to atleast have ago at making some

[stuartgallafant]

sounds a fair point to me. thats the initial reason that i gave up on the charger idea, coz i couldnt work out where to put the I/C... you look like you've done a really good job so far.

the worst thing that could happen though, is for one of those pipes to rupture and for the engine to suck in the water... BANG, i think is the word! although, im sure you've thought of this!!!

also, how are you going to keep the water in this system cool? are you running through a small cooler at the front, underneath the rad? and do you plan to use antifreeze in it? also, will this coolant solution be adequate to keep the temperature of the intake air down???

[David318is]

Hi appletree ,slightly off topic ,but did you use the proper tool for getting the cams out as I read that if you dont you can snap the cams .got to change valve stem oil seals soon

cheers

[appletree]

david318is, no i didnt i ask'd a man on hear and he does alot of stuff with m42's the problem is that at the cam shafts are holo they can and do snap if you have the springs pushing up against the shaft to much when you undo the bearing halfs you can turn the shaft as you undo the bearing halfs to some advantage although i did'nt as i only found out the above after doing the job i did set the engine to TDC on cylinder no.1 and then removed the shafts and had no problems

hope that helps in some way

as regards the charger cooling i am going to run the water/coolent through a oilcooler that goes in the front skirt where it would on a 325sport, the pump will constantly be running and hopefully the resivour will contain around 1.5ltr of liquid + the amount in the pipes/cooler/laminover which is quite a large mass, the other thing is that how often (apart from trackdays etc) do you run foot to the boards full boost?? most books seam to suggest you only realy run on boost 5-10% of the time so that means that 90-95% of the time the water is being cooled with out a large amount of heat being put back in to the system.

the other thing you can do is at sprints/drag put someting like Ice water in the system to give a realy cool charge

Another idea i could look in to in the futre would be running Aircon through the pipes! dont know if the power created would be enogh to over come the power need to run the air con?

as for the system leaking in to the engine the laminovas will have connections out side of the manifold so any leaks from the joints will be outside, the tubes will also be "floating" by being secured at one end and then a seal at the other end where they go through the end of the manifold to let the tubes expand/contract as the heat in the system changes with out putting to much stress on them. fatige is another thing i've looked at and it seams the roots type charger produces a pulsating charge which would easly work hearded a material like copper which i was origonaly going to use so i am using 1.5"x1.5" alloy bar now and running a 8/10mm hole down the centre and then making the fins 1-1.5mm thick to try and give the tubes some resistance.

[gareth]

And is it for sale??? PM me!!!!

or was you just taking the ****

it is for sale if you need it! it's spare from the M30 swap as i now have a HUGE M30 airbox in th way and a small suzuki vitara washer bottle on the old AFM bracket. i'll PM you in a minute...

Another idea i could look in to in the futre would be running Aircon through the pipes! dont know if the power created would be enogh to over come the power need to run the air con?

if you use an aircon pump for this, they disengage when you turn them off (electromagnetic clutch) so for drag races etc you can switch off adn use the chilled water with no drag from the pump other than running another belt over what is in essence another idler wheel. sounds like a good plan anyway!

[stuartgallafant]

matt, what kind of boost are you going to be running? if you are running anything above 5 or 6 psi, i reckon you'd need to lower the compression ratio. if so, have you thought about what you are going to use to lower it?

[appletree]

looking at running around 7psi, downing atlanta run this on the z3 m44 engine no probs and seen as they are a big company selling a kit to potentially a person who nows FA about cars with a big cheque book they must build a bit of safety in to the system if you no what i mean this is also not intercooled! most of the books seam to say 10:1 and 7Psi is ok above 7 you NEED intercooling. BMW do do a +size gasket aparently dont know how much .

am a right in saying that the early 325 lumps run 9.5:1 CR and a few people on here have turbo'd them ok, don't know what PSI they are running though?? anyone know??

[stuartgallafant]

yeah, thats right about the M20's

just thought that if you were going to run more than 7psi, you'd need to look at reducing the C/R and just thought you may have already thought about what to do

not to worry

[appletree]

ya it was something i worried about until i started to read up on the idea, three phone book sized books later i'am starting to get my head round it! LOL

any luck with a pic of the tesioner stuart??

[stuartgallafant]

dude, no luck as of yet, but PM tomorrow, as early as you can, and i'll see what i can do for you mate...

[appletree]

Will do cheers stuart, a pick would be great or just to know if it bolts on to the charger would be good as then i no if i can bolt it on to mine or if i it doesnt i know i've got try and make something up

[Guest]

dont listen to the wanker

[jkarran]

as for the system leaking in to the engine the laminovas will have connections out side of the manifold so any leaks from the joints will be outside, the tubes will also be "floating" by being secured at one end and then a seal at the other end where they go through the end of the manifold to let the tubes expand/contract as the heat in the system changes with out putting to much stress on them. fatige is another thing i've looked at and it seams the roots type charger produces a pulsating charge which would easly work hearded a material like copper which i was origonaly going to use so i am using 1.5"x1.5" alloy bar now and running a 8/10mm hole down the centre and then making the fins 1-1.5mm thick to try and give the tubes some resistance.

I doubt you'll have any failure problems with that setup. One thing that might be worth doing is puting a nice radius in the fin roots once you've been through with the parting tool,

To get more surface contact and turbulance in your water flow have you considered fitting something down the length ot the water bore. Maybe wind in a stainless spring like a helecoil (not a helecoil, something more open) or press a perforated 10x1mm ally strip down the center of the bore? It'd be a small gain but if you have access to a shear it'd be very easy to do.

I hadn't thought of it but the magnetic clutch off an aircon pump might be adapted to go on the SC if you're building a road car and fuel consumption is a concern.

jk

[appletree]

think you could probly modify the M62 to fit of the merc one, think the bypass setup will help the consumption alot when its half throttle

JK is your car going to be a track day only car then??

[jkarran]

No, not track-only but with no screen, plastic seats and 40mm ground clearence it'll never be my daily driver

I just meant that I couldn't care less how much fuel it uses to be honest I'd rather have the extra fuel consumption than an extra half kilo of magnet and wires spinning round at 16,000rpm especially considering the motor has no flywheel

jk

[stuartgallafant]

jk, can we get a full picture of the car, or even a few? i've wondered what this beast looks like for ages!!!

[jkarran]

Yeah, no problem. I just didn't want to swamp Matt's thread with non E30 stuff, that and the garage is a shit hole at the moment









It's still very much in its SVA ready state, orange side repeaters, huge wing mirrors, Sierra wheel, sticky labels on dash, 2" 4pt belts. I was too lazy/eccited to have it road legal to swap all that stuff out in the summer

It's a fun way to spend/squander money and bike engines are quite remarkable but it's scarey to drive, dry wheelspin in 4th is on demand if you're rough with it Should be fun once 5th's rendered dangerous too

The garage sums up my hobbies, interests and mentality very well

jk

[stuartgallafant]

jk, that looks f*cking man!!!

one of the lecturers at my training course has told me that is VERY VERY difficult to use a supercharger with throttle bodies, as i told him thats what i'd like to do on my M42... how are you going to battle round this?

[jkarran]

one of the lecturers at my training course has told me that is VERY VERY difficult to use a supercharger with throttle bodies, as i told him thats what i'd like to do on my M42... how are you going to battle round this?

Sheer bloody mindedness

If that fails I could resort to trick electronics on the bypass or whip the butterfles out and fit a suck through TB off something else.

Very very difficult = interesting and rare! If it was easy then everyone would be at it To be honest, the easiest thing I could have done is buy a turbo kit from Holeshot but there's no fun in that.

Inspired by a mates mid engined R1 Mini I was thinking recently about what next... two of these bad boys (or 9Rs on the cheap) in a gutted E30 would be 340bhp 4wd and 6spd sequential.

jk