Supercharger build up

[Shadowbug]

Well I got my supercharger the other day and have begun prep for install

supercharger is a roots style unit from a Toyota 4AGZE (j-spec)
the engine it came off is 1.6L it will be going on my freshly rebuilt 1.7l Type 4

the engine has been converted to 911 style cooling, its basically a stock 914 1.7L with a cam

intake will be a custom fabbed unit made from mandrel bent tubing using stock type 4 intake as a base (cast pices with intake bosses) and will run a megasquirt FI.

The S/C has a magnetic clutch so with the flick of a switch I can run normally asperated. still got to take the clutch assembly apart to see if I can make a spacer to fit between it and the main unit, so I can set the Supercharger back further but still line the belts up just right.

I'll post pics soon

[Shadowbug]

ordered my megasquirt today.
also beadblased and painted (might blast it again and clearcoat instead) the supercharger.

still have to decide if I'm going to make use of a intercooler yet. it would be a good idea, but with just 8psi of boost, there might not be any need for it.

Will post more pics as it progresses.

http://scage.3sgtemr2.com/beetle/supercharger1sm.jpg (http://scage.3sgtemr2.com/beetle/supercharger1.jpg)

[yetibone]

That rocks!

A buddy of mine had a supercharged MR2 a few years back, and man what a hoot that car was to drive! Totally smoked my old '88 Supra back then. :o

The clutch drive was computer controlled, and was unlocked during any running state other than accelleration, and high speed running. Pretty slick for maintaining good MPG's.

An intercooler will be a good idea, regardless of boost pressure. The cooler the air, the higher the oxygen content for a given volume.

[Shadowbug]

Ya the sid\ze of pullies I'm going to be running to drive the Altenator and S/C will mean I'm putting out more than 12psi boost, so Intercooler is not an option, its a requirement.

I decided to do a partial rebuild on the S/C which involves replacing two of the bearings, but because these bearings are not avaliable in north america, I've decided to run a double ball bearing setup sleaving a 40mm od bearing to fit the 45mm bore.

the rotors look to be in good shape so they were just carefully cleaned, lubed up with vasalene (to prevent oxidation) and stored away.

the main case and gear cover were bead blasted (again) and are being powdercoated "almost Chrome" before reassembly.

there is very little scoring on the machined surfaces, this will be hit lightly with 1500 grit wet dry to ensure thay won't cause any further scratches on the rotors.

Will post pics as I begin supercharger reassembly, and when my megasquirt kit arrives.

[Shadowbug]

Gut my megasquirt today and have begun assembly, also rebuilt the supercharger, powdercoated a different color too.

first order of business after the megasquirt build is the intake manifold, plan is to build it so I can bolt the TB directly to it in order to run N/A and get it tuned in, then add the Supercharger. I need to figure out pulley sizes to drive the supercharger at the correct speed, cause the teflon coating begins to melt at 14psi, which is WAY higher than I want to run it, I'm thinking 8 psi is max.

I wish I had my own machine shop, or at least a Lathe, it would speed the process along considerably. Pulleys and the toothed wheel for ignition need to be machined to get it all working together.

[volkdent]

Sounds like a lot of fun!!! Get those pics up so we can ride along with you on this little fabrication journey.

Jason

[Shadowbug]

finished the workover on the engine, the guy who I had build it did a pisspoor job putting it together and there were a few issues I wanted to fix before putting it into service.

#1 oil leaks, brand new build and it leaked like crazy, so I dissasembled the top enf cleaned everything and redid the pushrod tube seals, Beadblasted and powdercoated the pushrod tubes, and coated the seals with silicon before reassembly. also did the picup plate and the othe plate on the bottom (I think it was for some industrial application)

#2 oil pump, rather than doing it properly the builder opted to grind down the heads of the bolts holding the cam gear onto the cam. and when they still hit, he cut a gasket out of thick rubber to space the oil pump out. of course when you tigten the oil pump down the gasket squishes out and provides no seal whatsoever. so I pulled the pump and ground a little off the back side for clearance, slid it back in with a regular gasket and clearance is fine.

now that the engine is back together and hopefully drip free, I will begin on intake fabrication. I rebuilt the supercharger (it was a matter of replacing bearings that couldn't be found anyware this side of japan) and will need to fabricate mounts for it, as well as machine the ignition pickup wheel/pully to fit onto my engine, and find matching 6 rib serpentine belt pullies to use on the supercharger and altenator.

so I do have my work cut out for me, but things should be strait forward, as I know where to get the pieces I need, but have to get most of them machined up to fit with what their intended use would be. I wish I had a Lathe at least.

the pulley setup I was running with my porsche fan gave about a 1 to 1.5 ratio on the altenator, Jake Raby figured this was too high, would a 1 to 1 or a 1 to 1.2 be alright, cause it looks like this wouls be the easiest to do

[Shadowbug]

heres a couple pics of the current status of build
click for larger pics

http://scage.3sgtemr2.com/beetle/engine/build2p1sm.jpg (http://scage.3sgtemr2.com/beetle/engine/build2p1.jpg)http://scage.3sgtemr2.com/beetle/engine/build2p2sm.jpg (http://scage.3sgtemr2.com/beetle/engine/build2p2.jpg)
http://scage.3sgtemr2.com/beetle/engine/build2p3sm.jpg (http://scage.3sgtemr2.com/beetle/engine/build2p3.jpg)http://scage.3sgtemr2.com/beetle/engine/build2p4sm.jpg (http://scage.3sgtemr2.com/beetle/engine/build2p4.jpg)
http://scage.3sgtemr2.com/beetle/engine/build2p5sm.jpg (http://scage.3sgtemr2.com/beetle/engine/build2p5.jpg)