My supercharger build: Update 7/5/2010 Emanage!

[anothernord]

Thanks guys! Small update: I routed the BPV back into the intake, right after the MAF, and I think the surge of air at idle is backing up past the MAF, causing the unit to read incorrectly, and cause idle "hunting". Its not too bad, and it probably is leaking at various spots.

I tried a setup without the intercooler, and it really didn't help much. Power was maybe a little better, but the pipe would get badly heatsoaked and low-end torque was terrible, so back to intercooled I went. I think boost went up maybe 1 psi, according to my not so accurate boost gauge.

[anothernord]

Ok, so I got an actual mechanical boost gauge that doesn't read wrong because of my altitude, and it turns out I am only getting 1 psi. Cause? Belt slippage, and major boost leaks. I noticed that RPM's would rise, but boost would just stay at 1 psi. This is good news because it means I can get even more power out of my current pulley setup. Sometime I will be getting a smaller fixed SC pulley, probably not for a while because I just dropped a ton of cash for textbooks, and I have to fix all the vacuum leaks so it will idle correctly with the SC on.

On a funnier note, I was sitting at a stoplight while on a drive testing the drivability of the car when the SC is always on, and the idle is going all over the place; it sounded like I was revving the engine. So a crotch rocket rider pulls up next to me, hears the crazy idle, and begins to rev his motor in preparation for a street race. I tried to say something like, "its just idle hunting!! I don't want to race you!!", but the light turned and the biker took off.

[anothernord]

So the idle hunting turned out to be several leaks both on the intake and pressure side. I fixed most of them, and it is near perfect; that is, it idles fine, and drives normally, except a lot more power and noise!

[xXGTBspecXx]

you sir have a PM...

[anothernord]

PM returned.

[xXGTBspecXx]

your kit is crazy...

you need a outside video of you driving by getting into it!!


id get crazy like kenne bell massivly loud supercharger whine..

[Airgne]

+1 on geting a video of it running and driving. you might wanna look at making a kit for some ppl on the forum. reason has his business license, and im sure he would be up for it. also it might help his 95.7whp he has.

[xXGTBspecXx]

actually thats what my PM was about

[Airgne]

actually thats what my PM was about

^good.

[anothernord]

I'll try to get a video soon. As for the kit, I would be up for it if I didn't just start classes. I just won't have time, and all the tools I would need are at home, and I'm only there a little bit on weekends. My design needs some major revisions too; like an actual way to tension the pulley, and more efficient intake piping.

But videos I can do. Its been pretty funny driving around campus; definitely turns heads.

[Airgne]

^ cant wait.

how much did the total cost come out to be?

[xXGTBspecXx]

around $1000 for everything... im reading up on skidd's setup...

il be doing this in the near future...

[anothernord]

VIdeos!!

[jey]

You're almost out of gas

[Airgne]

nice. bigger pulley

[Reason]

We need outside video drive by's and dyno numbers!

[rougeben83]

hook up that boost gauge!

[anothernord]

hook up that boost gauge!

Sadly, it is; I'm barley getting 1.5 PSI I blame inefficient piping.

A 2.75" permanent pulley should fix that though. 5 psi

You're almost out of gas

Less weight FTW!!

[hink01wag]

its not the piping... unless its leaking. the pulley on mine is 3 1/2" and im only getting 5psi... your pulley on the SC looks to be the same size as the power steering pump. you need to get the SC pulley smaller. its a lot more fun!!!

[anothernord]

its not the piping... unless its leaking. the pulley on mine is 3 1/2" and im only getting 5psi... your pulley on the SC looks to be the same size as the power steering pump. you need to get the SC pulley smaller. its a lot more fun!!!

Yep, SC pulley is 3 3/8", and PS pulley is 3 5/8". 2.75" pulley should give me a 1.9:1 ratio that I need.

[anothernord]

So some updates: I have decided to keep my electric clutch pulley and instead get either a larger crank pulley with a matching larger alternator pulley, or a special power steering stepper pulley. The electric clutch, as I have realized is awesome for those times when attention is not needed. It also helps keep mileage where it should be, since I can control when the SC comes on and off.

So look for some new pulleys here in the next month. Hopefully I can get one made without going totally broke.

[d1giPhux]

Nice work man.. just keeps getting better and better!

[impreza_GC8]

Very nice. I'd be interested to see what numbers it puts down on 8psi. I'm running 11 out of my turbo setup and yearning for more. I think that an SC setup wouldn't be able to satisfy my power craving but the fact that you've got only around a grand into it from what I can tell puts you ahead of the game because any turbo kit/conversion/swap is gonna cost much more than that.

[anothernord]

Very nice. I'd be interested to see what numbers it puts down on 8psi. I'm running 11 out of my turbo setup and yearning for more. I think that an SC setup wouldn't be able to satisfy my power craving but the fact that you've got only around a grand into it from what I can tell puts you ahead of the game because any turbo kit/conversion/swap is gonna cost much more than that.

I'm hoping to hit 180-190 WHP on 5-6 psi, and if I go higher, possibly 220 WHP. I'm wary of going higher than 5-6 psi though, since the engine does have stock 9.7:1 internals. Even now with the huge SC pulley, its still a blast to drive compared to stock. I can only imagine 8 psi.

[anothernord]

So, another update: I have finally fixed the stumbling and rich idle issues! I though I would never get around this problem, but all that had to be done was moving the bypass valve's outlet farther downstream from the MAF. Before, the air would come out right next to the MAF and mess up its signal.

So, this means that I can now get a permanent SC pulley, Yet I'm still weighing options. The thing is, if I get a new SC pulley, I'll have to cut up the exist pulley to get the special female spline end off, so it can be welded to a new pulley. That means I can't put back on the electromagnet clutched pulley unless I find a spline section somewhere that matches the Mercedes' splines.

Edit: Sourcing another spline piece from a Mercedes forum. Hopefully I can get a custom 2.75" pulley in the next couple weeks!

[anothernord]

Ok, a 2.6" permanent pulley is 100% a go. It should give me 6 psi of boost! Colder plugs will finally go in as well.

The pulley should be here hopefully by next weekend, so look for some updates then!

[iampetro]

videos

[anothernord]

videos

See several posts up; in the middle of the page.

[anothernord]

The custom pulley is in the mail! It is a 2.6" 4130 steel pulley, and the design requires that I press in the bearing. This basically involves putting the pulley in the oven at 350 for a half and hour, then using a gear puller to press the bearing in. Then I'll have to drill and tap holes in the pulley itself, and drill holes in the front spline plate. If all goes as planned, I should be boosting to 5-6 psi this weekend.

[anothernord]

Well, nothing ever goes as planned. I received my new pulley, but I found that I won't be able to just drill my spline plate and attach it to the pulley; I'll have to have the spline plate cut out, and have a disk welded to it, then drill and screw it to the pulley.

For now, though, I removed the entire setup and threw on my old CAI. This way, I can put in the new colder plugs and new wires without removing everything again after I figure out the spline section over this week. Plus I can have the SC out to put new roller bearings in, since the current ones rattle like hell.