Project-M45 super charger (developments)

[tim_s]

nice one dude, keep us posted! looking forward to this. you sure you don't want to use a bigger eaton SC like the DASC?

[lentec]

maby enough room for a laminova core inside that?

[appletree]

Hi Lentec
What exactly is a laminova core? Obviously some kind of heat exchanger! Matts Dad

[lentec]

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

[appletree]

that looks pritty cool! lentec i had thought of running a 1" tube through it and running water through that but you're idea with the fins is even better!

tim, if you look at DASC site it says they only run 7psi boost something the m45 should be able to do easily. the only reason i can think that they used the m62 is beacuse if its bigger then it wount have to work as hard to do the same amount of work and there fore wont make asmuch heat and as they arnt running any kind of cooling keeping the charge cool is even more important than normal. also if this works, who knows with the amount of mini super chargers about on ebay i might be able to sell it as a kit

[tim_s]

ah fair enough dude!

[stuartgallafant]

i've just caught up on this. its been a really interesting read so far, and i remember what i was planning when i thought about using a Mini supercharger for my iS. although everyone managed to talk me out of it and i soon gave up on the idea

i really have to get my arse into gear and write up my engine project!!

keep up the good work, it looks outstanding!!!

[Demlotcrew]

Just get this and be done with it,

http://cgi.ebay.de/BMW-E36-Z3-Hartge-Tr ... dZViewItem

Andrew

[stuartgallafant]

dude, i want that hartge engine!!!

i've heard of this, but never seen it, and now i know its real, i want it bad!!!

[appletree]

Heres a few more pics of the manifold progressising.

this is what it will be like when bolted up to the inlet.



boring out the holes for the inlet



this is a pic of the manifold with the bores all machined out to match the inlet


i cut a groove in the bottom of the box to make it bend in the correct place and to stop the sides destorting. i also cut the top side ready to open out and weld the strip in
.


the manifold has know been split along the top and opend out to fit a strip of 2 3/4" flat bar in the top, its all ready to be welded up so al get some more pics up as it takes shape.

[lentec]

Looking good matt

[jkarran]

Coming along well. Mine's taking ages as I'm beating the plenum out of alloy sheet and I'm having to learn how as I go.

I'd put some pics up but as it's not in an E30 I doubt they'd be of much interest.

Bet that milling machine helps

jk

[Demlotcrew]

Hey ive got loads of charger bits, your more than welcome to make an offer (would take their worth in weight)


















Andrew

[appletree]

Hi really nice looking stuff do you know what they are off, do you have any pressure control valves sensors etc. How many ribs do the pulleys have please Matts Dad

[Demlotcrew]

They are for V6 and V8 merc engines. No sensors sorry.

Andrew

[appletree]

Put some pix up JK all engineerings interesting Matts Dad

[appletree]

hears some more pics of the manifold welded up.
just got to put some balnks on and then some kind of water cooling inside. at the moment its looking like turning out a laminover cooler out of two bitrs of alloy bar.

from the front



from the side



and bigger from the side



Also hears a pic of the mini inlet i have for sale. sorry it took so long to post up jkarren.

[Toby_Unna]

that's cool

wish i had some of those machines

[jkarran]

that's cool

wish i had some of those machines

Exactly what I was thinking.

Matt/Matts dad, that looks sweet and is progressing way too fast!

I need to get my plenum and intercooler welded up pronto. I've opted for cutting the end tanks off a CooperS cooler (simply because I had one and it's roughly the right size), one end will weld direct to the plenum, I will have to form a new end tank for the other that will go very directly to the M45 which is going to sit down behind the gearbox on my R1 engine. A fan and cold air duct should stop heat soak from the gearbox spoiling the cooler efficiency. Should be neat if it works (but not as neat as hiding a core in the manifold!).

Will snap a couple of pics when I think on but as it's a Yamaha powered kitcar they'll be of limited interest. My E30 is too rough to deserve pictures but I love it!

Cheers for the inlet picture, it looks nearly as big as my engine! No way will that fit, pity.

jk

[lentec]

How many ribs do the pulleys have please Matts Dad

How many do you need/want?

[appletree]

at its moment its looking like using the pully of and 1.8 e36 m40 engine if i've got that right its a 4 groove flat belt with ba v-belt pully on the end of that it should run the PS and A/C but the flat A/C pully will run my charger. the pully on the S/C however is a 6 groove. so any 6 or 4 grove pullies.

am i right in saying your m62 has a 4 groove pully lentec?

[appletree]

Just for the record this is Matts project and his work (except his mate's done the welding). I just side band now and again and ask questions when hes at work/working away. matts dad

[lentec]

No it has a 6. You must have a lathe? i can get cast aluminium blanks you can cut as many grooves as you need

[Turbo-Brown]

Is that plenum steel or ali? Guessing it's steel by the heat haze near the welds?

Very neat

[appletree]

Plenum is 316 food grade stainless steel Ya got a lathe when you say blanks wha tdo you mean? what price? are they the pullies with out any grooves or just alloy blocks.

[lentec]

By blanks i mean undrilled no groves cast aluminium.

This one has been drilled/groved but you get the idea.
I can get them for about £85 inc. in unfinished state
But the company that casts them do have about 3-4 week turnaround.

[appletree]

cheers for the pully info lentec somefing to keep in mind.

hers a couple more pics of the next step the charger mounting plate


Marked out ready to cut out the charger shape,once done this will be welded on to the manifold and then the charger will bolt to that.



a rough idea of how the super charger will mount to the plate

[appletree]

well i had a very productive day to day, got loads done and moved the project on a good bit.

booked to day off as a holiday with the idea of doing just alittle to the projectand have ended up doing loads!!

firstly i did the battery in the boot conversion like on the 325 sports but rather than to supposidly to compensate for the weight of a heavier back box i thought it would keep the balance as the battery and the super charger weigh about the same.

the other plus is that if for any reason there should be a fire under the bonnet is possible to disconect the battery with out opening the bonnet and letting more air in.


any way back to the main project

quick pic of the plate chopped down to fit the S/C



hears a pic of the lugs i had to remove in order to let the S/C fit flush to the new manifold.



these are a few of the S/C and the plate/manifold all bolted up (to be welded but i bolted it all to make sure it worked first.) if you look closley in the second pic you can see the different crank pully, this is normaly a twin "V" belt pully but i now have a flat belt (to drive the S/C) and a "v" belt for the power steering.








hears the plate all stich drilled out, this was to save time with the milling.



the above plate being milled to the correct size.



And finally the plate bolted to the manifold ready for the manifold to be cut to the shape of the plate and welded on tomorrow.




all in ad ays work, and wrighting all this is like a big version of my GSCE project. LOL

[maxfield]

[jkarran]

Nice work as usual.

You can totally remove that rear plate (with alternator drive?) from the SC rather than cut the lugs off, the gears that keep the lobes meshed are the other end. I did that with mine, to save weight I replaced it with a 3mm alloy cover plate (400kg car, ever gram counts).

As your pully is going to be fairly small to get a reasonable pressure ratio it'll surely be cheaper to machine it from ally bar stock than cast blanks and you'll get exactly the ratio you need. That's what I plan to do but I also need to make a crankshaft extension and bearing carrier/oil seal (there's no external pullys on a bike engine )

jk

[lentec]

Good work dude but how do you plan to get to them manifold bolts when you have endcaps on?

[jkarran]

I wondered that but the inlet flange will be big enough to get a (skinny) arm and ratchet spanner in through surely, he just hasn't cut it out yet. Except it sounds like it could be full of heat exchanger in there so...

It's going to look in the car though

Are you going to radius the holes where the runners meet the manifold Matt?

jk

[appletree]

ya i thought some one would ask how i am going to get to those middle bolts, and the ansewer is the two end caps will be linked together by the 2x heat exchanger tubing 1 1/2" alloy bar with a 8/10mm hole down the middle with fins machined in to it and will also act as a draw bolt pulling the two end caps together and sealing against the manifold.

You can also get to the first 3 with a small socket/rachet throught the charger plate so they can all be bolted up no probs. the other thing is that because its not to big i can get to all the head/linlet bolts with the S/C all in place so i can build it all up then bolt the hole lot on.

As for the runners, ya i think i am going to try and make them run in smother probably attack them with a die grinder and a flap wheel.

[d6dph]

Quality stuff. Really great workmanship

[appletree]

cheers dave, my dads tought me alot and now i'am abit older (19) i'am starting to do the work my self and as he said abit ago, hes just side banding and offfering the advise every know and again.