Project-M45 super charger (developments)

[jkarran]

Interesting idea on the cam tensioner, that's the kind of thing I'd like to use but my concern is still the running speed @70mm od it'll be hitting ~14,000rpm. In the Scooby it wont see over 5000rpm.

What does it weigh roughly? I'm quite tempted but if it's heavy and costly I can still make my own small dia 30,000+rpm roller for £30

How'r you getting on with the belt setup and coolers Matt, must be getting close now?

jk

[appletree]

550g JK it is a needle roller too which is good!

[stuartgallafant]

needle rollers dont really like mega high rpms. JK, if i were you, i'd make my own! for the sake of £30, at least it'll be exactly what you want

[jkarran]

Pretty much wat I was thinking, the Scooby unit looks ideal for a lower rpm saloon setup but the weight is a concern on mine (how anal am I being ) apart from that it looks cool, I'll be copying that adjuster mechanism! I think I'll be sticking with needle rollers though for the thin section (more id for adjuster mech) and high load ratings.

jk

[stonesie]

how wide is the belt again?

I serviced a E36 318 today and was thinking that the air-con belt tensioner looked a simmilar thing to that but only about 20mm wide

[appletree]

Might be usefull what type is it?? spring loaded trailing arm??

The belts a standard 6v bmw belt IIRC about 20mm

[appletree]

Not much progress on the S/C front at the moment, as i have decided to build the car back up N/A and get a MOT incase the emissons are stupid when it gets S/C.

I have still been moding it though and have just fitted a Sebring Back Box.


It seams that out of all the exhuast manufactures who made exhausts for the IS (remus, supersprint and Sebring) have discontiued the range so the only chance of getting one is to try and find some one who keeps them on stock which no one does as they are sent to direct form the factory.

However after nearly 2 days of ringing around and searching through ebay, mags and google i found Larkspeed had 2 and so ordered it there and then.

hears a few pic of the new Back box.

Sat in the back of my italian wrongness.


Next to my origanal exhaust


Fitted to the car

[Gunni]

You´ll only get bad emissions if you have bad tuning,
don´t waste time by making it NA now and then later SC,

[appletree]

It will be set up right its just that the MOT will run out around the time when i am going to take it to be setup and so i need it road worthy and as i know it all works NA i though ad get it Mot'd NA so i dont have to worry about anything like it failing a MOT before i get chance to take it and get the S/C set up mapped.

[jkarran]

Doesn't sound like a bad plan. I'm going to do the same with mine, partly so I can move it across the garage and partly so I can enjoy it on sunny days while I work on it, maybe get some enthusiasm back. The weather should be much improved when I get back from holiday in a couple of weeks.

jk

[appletree]

Well the beast past the MOT no adviseries

Now thats out the way i've stripped the inlet manifold and replaced the injectors with some larger ones and tested them on the N/A set up to check they work. They did, and were quite alot quiter than my origonal ones.




Started to make the inlet pipe for my throttle body this is what it should look like minus the balck join hose.



just held in place.



and welded and polished up, the first hose tailis for the cam cover breather and the second is for the ICV.

[gareth]

looking good! very nice hoses there too.

lucky on the mot pass too! when i worked at a garage, that only ever happened once. it's happened to my wife twice (1991 corrado, 1992 E34 sport) but never to me

[appletree]

when i bought it the last MOT said track rods, then it past a second one last year no probs and then this year i put new rods on and it sailed through!

[bobafett]

[quote="appletree"]Well the beast past the MOT no adviseries

Now thats out the way i've stripped the inlet manifold and replaced the injectors with some larger ones and tested them on the N/A set up to check they work. They did, and were quite alot quiter than my origonal ones.




What injectors are you using, are they BMW ? If they are what from....Cheers mate

[appletree]

No there Rover K-series, these ones are from a mg zr 1.4 16vSI or so i was told, they are physicaly the same size/fitment. I got Dave walker at emerald to suggest what injectors i needed and he gave me the part number for these.

they should give enough supply for 200bhp working @4bar with a 80% duty cycle.

all though they are from a 1.4 acording to the bosch injetor list they do flow more than standard IS ones

[stuartgallafant]

matt, i managed to get hold of some injectors from a MINI cooper S. only have 7 miles on them too!! barely got wet!!

do you know anymore about that turbo manifold you were talking about?

[appletree]

Try this link courtesy of dibs http://www.666fabrication.com/main.html
matts Dad

[stuartgallafant]

cheers!

[Lennerd320i]

what a nice project! a lot of pics and interesting way of working + information! great job that you've done so far

I'm wondering what the results are going to be!

[appletree]

had a good week this week and got loads done heres the tensioner ive spent ages making, not realy coz it was hard to make more the design that took ages!!!

Heres the tnsioner mocked up in wood, theres a block at one end and a exentric shaft at the other so that the whole set up can move back and forth and rotate around the block to make the pulley run perfectly true



When i make the ally version the end slot will be blind withan adjuster screw to do the tensioning against the exentric shaft.



These are a few pics of the almost finished set up, just got to trim some of the plates up to make them neat. as you can see the whole lot is all bolt on and only has the inlet/head nuts to tightn and my 2 brackets and mounts to bolt on and the "kit" can be fitted/removed










Heres me holding the finished set up, yes it is heave!!



Heres two pics of the tensioner in place on the car with the belt tight, the pulley is aBmw one from an E36 318 this means i know it will be up to running at the belt speeds as the crank pulley thats running my S/C was also from the same car.





This is what my Dads been playing around with while ive been doing the tensioner hes fitted to 3phase motors to the lathe running on inverters so the lathe can run from as low as 3/4rpm in back gear upto around 3000rpm(120hz) the second motor which is on the cross slide is for machining the lamanover cores and runs from 8rpm to 1800rpm.

we're goin gto experament on some 1.5" square wood to sart with to determine speed feed rates and depth of cut.

We'll progress to ally billet then the real thing.

[gareth]

fun fun fun!!!

[jkarran]

Good progress in the last couple of weeks Matt

Love the slitting saw settup, that looks totally lethal

jk

[appletree]

Belt guard was not omitted for clarity, it aint got one. Matts Dad

[gareth]

kinda like my dads power hacksaw! open drivebelt and totally oncovered 18" 5 spoke iron flywheel with the on/off switch in the 6" gap between the saw and flywheel! the best bit... reaching through the belt to get to the button unsuprisingly we switch it on and off at the wall!

[oze30]

Belt guard was not omitted for clarity, it aint got one. Matts Dad

Quality!

Home brew mechanics at its best! Good luck with it all!

bet you cant wait to hear that lovely supercharger whine!!!

[appletree]

It breaths



After my earlier post i have managed to get the car running at a pritty smothe idle around 1000rpm after i adjusted the stop on the throttle as i think the ICV could not cope with the amount of BHP that the S/C required at Idle.

Since then i have been out for 3 short runs in the car without the laminovas (intercooling) and have had around 0.35BAR boost.

As i have not much space to fit a HUGE air flow metre in in the finished set up i had to jubilee clip a rag over the inlet to act as a air filter. On the 3rd run i removed the rag and put some ducting right to the front of the head light and on that run i got just over 0.4Bar.

On the first runs it felt quick and there was no pinking or knock however on the third run it realy shifted and then i did get a little pinking but when i checked the spark plugs they did look like it had been running a little lean so i'am going to get an adjustable fuel reg and try again to see if that helps, also going to have a push at getting the laminovas finshed.

i do have a vid if any one could tell me how to host it or do it for me??

[Silverfang]

i do have a vid if any one could tell me how to host it or do it for me??

I've got a youtube account if you want me to host it, though it's not hard to get your own

Good looking project so far though

[appletree]

I've join'd youtube and hosted the vid now so hopefully this will work

In the vids its running on the standard AFM so all the pipe work is a mess but it ment that i could take it down the road and properly test it which i did!

Just a quick vid i did on my phone.

[fowler]

very good work love home mechanics
best of luck
F.I is the only way to go

[schuey]

Good effort that man!

[appletree]

Cheers fellas it nice to know some one else appreciates the workive put in to this project.


So does the link work then? ive searched on you tube for my vid but i doesn't come up? only if i click a link streight to it?

It hasn't finished yet still got a bit more to do, like pluming in the bypass under neathe, tidy all the pipes up and then sort out the management! :

[tim_s]

[jkarran]

Good effort Matt

Mines going on the back burner for a bit It's too sunny to have the car laid up in the garage so it's going back on the road NA while I try to get motivated and get the remaining bits together.

jk

[mick_318is]

Matt ( and Matts Dad )
That sure is looking

Without looking back over the entire thread is the 0.35 - 0.4 Bar what you were expecting and what should that equate to in BHP???

Mick

[appletree]

I'am not to sure about the 0.35-0.4 bar pressure as the gauge i used is not sitting at zero when its not connected so i could be more, the charger is set to run at max RPM so it should be making as much as boost as posible. As for BHp i realy dont know as its not mapped ur running the right amount of fueling yet but as it is its got loads of torque and is pulling well.

have to wait and see, the R+R is now booked for june 20th

still lots to do till then though.

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