Mini supercharger on 1zz

[Carolyn]

So we rigged up a puller that spreads the load, and applied a bit of heat.  Stuck.  Gave it as much force as reasonable.  I don't believe this would come off with the specialist puller either.

We're going to cut it off, I'm afraid, so no sample for making the new one.  On the other hand, we know the shaft diameter and the groove pattern is the same as the idler pulley.

[Blue al]

I'm sure I have some spare mini pullies to hand if it helps reverse engineer what you need

I'm new to the forum but wife owned a 2005 mr2 from new to 70k,
so fairly familiar with the car, serviced by Matt @ Silverstone performance

Hopefully I can bring somthing to this thread having ran a supercharged r53 MCS and over 2008 squeezed another 100 or so bhp out of it, sold on at 140,000 Miles end of last year, still going strong on std bottom end, oem clutch and gearbox

Stock injectors 340 are good for 170 bhp

Jcw injectors 380 are good for 210 bhp

440 and 550 injectors used by various mini tuners to over 300bhp

[lamcote]

Interesting, what mods were required to get a 100bhp increase, also what boost pressure? I have read on Mini forums that the M45 supercharger doesn't easily deliver more than c.240bhp, did you have to modify it? Thanks

[Blue al]

In summary (ignoring lots of additional supporting mods which may or may not have added ponies along the way)

240 bhp with 17% pulley, janspeed manifold and miltec cat back exhaust from 10k -30k

270- ish, with newmancam, ported, polished Valved head, 440 injectors custom tune, bigger intercooler from 30k to 90k

Last few hp found with -20pulley 550 injectors, catcam, Aquamist water/meth injection  (as supporting mod for track temps) from 90k to 140k

Not sure on boost, as bigger intercooler and better flowing head reduced obd values, but around 18 psi at stage one,

Only unexpected cost beyond modding was for an additional supercharger brought at 80k just in case, and allowing car to be daily driven whilst spare was cam coated ( Warrington)

[lamcote]

Great thanks, are newmancam and catcam sports camshafts?

[Blue al]

Yep different lift and duration overlap etc

Mini only needs one, just choose where you want the power to arrive

[Blue al]

Kavs is the man who can provide custom mini pullies
He has done all mine including fitting an upgrade at Santa pod in 20 minutes (2 part item makes swaps easier)
He also can help with another popular choice   s:D s:D  

 m http://www.kavsmotorsport.com/lotus-sup ... ey-upgrade m

Apologies if link is stepping on anyone's toes still learning the ropes here

[Carolyn]

Kavs is the man who can provide custom mini pullies
He has done all mine including fitting an upgrade at Santa pod in 20 minutes (2 part item makes swaps easier)
He also can help with another popular choice   s:D s:D  

 m http://www.kavsmotorsport.com/lotus-sup ... ey-upgrade m

Apologies if link is stepping on anyone's toes still learning the ropes here

Nope, such links are very welcome and helpful.

New development.  We've figured out and fabricated the supercharger outlet and got the exhaust manifold mod under way.  We've looked, measured, sucked teeth, measured and discussed the subframe.  We've come to the conclusion that an existing subframe can be modified quite simply to accomodate clearance for the super charger.  Makes the whole project much more practical.

Will post pics in the next few days.

[Essex2Visuvesi]

I'm still following this one and will help out where I can  s:) s:)

I'm now investigating the 13B-REW or Renesis route   s:oops: :oops: s:oops:

[Carolyn]

Looks radical.  We'll plate it in using heavy guage steel.  This is a practice piece, we'll be using a better condition subframe.



S/C outlet:

[lamcote]

After doing a lot more research on pulley sizes I am wondering if 120mm is going to be too Conservative? There is so much conflicting information and too few actual tested projects out there to be confident about the impact of pulley sizes on any given engine that has not been popular with supercharging, ie ours! I do wonder whether we ought to have a few sizes to experiment with eg 120mm (if now made), the standard 65.5mm and one somewhere between 70-80mm as may be available. Any thoughts?

[Carolyn]

I'd already decided that 120 mm did not allow for lack of efficiencies caused by a ducting system that is, by necessity, cruder than the original Mini sysyem.

Done some figuring, and wanting not to over-do it, we're at making a 105 mm pulley.  Trying, also, to avoid the need for an intercooler.  We want to start with a very simple set-up which can evolve as we get to know it.  Remember, I'm not that interested in performance at high revs....

[lamcote]

Agreed, as you say the inlet tract will inevitably be suboptimal compared to the Mini oem setup. Even 105mm might end up being too big but let's give it a go and see where we finish up. Is it fairly easy to swap the standard pulley back on if needed for testing purposes? Of course, whilst top end performance is not a concern, if it can't potentially deliver at the top end it won't produce bottom end either.

[Carolyn]

What standard pulley?  It's been cut off.  When you're doing these kinds of projects you can't keep going backwards and forwards.  Something gets built, then tested, then developed.  The original pulley would still give more boost than I want...

[jonbill]

Gotta keep moving forward  :-) :-) :-)  
Will the exhaust come over the supercharger, or behind it?

[Carolyn]

The exhaust goes over the top.  Going to need a heat shield and wrapping.  We're extending a Toyosport by cutting it at the head flange and welding in more S/S tubing.  How we work the rest of the exhaust remains to be seen.

[Blue al]

What standard pulley?  It's been cut off.  When you're doing these kinds of projects you can't keep going backwards and forwards.  Something gets built, then tested, then developed.  The original pulley would still give more boost than I want...

See the base of this page, the chart is mini focused, so not the sizes your considering
See how dramatically the charger rpm drops, which means cooler running
I'm sure kavs can figure out numbers or you can plot from these,
The compressor efficiency maps are on the net somewhere I will dig for them if you don't have them to hand


 m http://www.kavsmotorsport.com/mini-tuni ... ger-tuning m

[lamcote]

It would be useful if we could see how the boost changes in line with the pulley sizes, the maps would help.
It seems that the design of the inlet tract has a massive impact on the boost produced so with no intercooler and a very different outlet pipe compared to the Mini we really are in uncharted territory so actual testing is the only way to find out what this setup would produce.

[Blue al]

 m http://www.eaton.com/ecm/groups/public/ ... 128483.gif m

Looking at the map we should be aiming at around 8k or more ?

I was spinning it off the map for my car,  20% and 7450 rpm but r53 minis come with forged rods and intercoolers foc from the factory, I had upgraded the intercooler and also water meth injection, and was  happy to trade potential max hp for off the line low down grunt and torques,
so it might be worth spinning it a little faster than think you need, if your happy the engine can handle the boost, for a better overall 2 -5k rpm pre lift package even if the headline numbers aren't quite so good

[lamcote]

I think the R53 is a Gen 3 supercharger, I wonder how different that would be?
Also, isn't that showing max efficiency almost down to 4,500?

[lamcote]

Just doing some calcs based on that map.

With a 105mm pulley and an anticipated pressure ratio of 1.2-1.3 we would be running the supercharger pretty much right through it's maximum efficiency range on the 1zz. ie 1,500 to 8,500 supercharger rpm at 1.3 PR.

Assuming 105mm gives a 1.2-1.3 PR, which it might not quite. But it is a sensible starting point. If we can get to the point where we have a pulley to deliver that boost level it looks promising.

[Anonymous]

1.2 bar??

[lamcote]

Yes and no!

1.2 bar absolute. ie 3psi boost as more usually described.

[Anonymous]

Gotcha was going to say I doubt the charger would even get to 1.2 bar boost.

I'll get back in my seat with the popcorn and carry on watching.

[lamcote]

All comments /thoughts welcome, this is a voyage into the unknown so the more input the better in my view.