Mini supercharger on 1zz

Carolyn · August 16, 2016, 09:52

Quick update. David is making two pulleys. One 105 mm and one 115 mm. We've decided to strip down the supercharger and give it a good clean and service. While it's apart, David is going to put a key-way into the shaft. He's putting them in the pulleys too. We decided that interference fit would be a pain if we want to play with pulley sizes, so a key-way it is.

Blue al · August 16, 2016, 13:06

Might be handy for a charger rebuild

m http://www.gtt.uk.com/product/mini-gen- ... e-coupler/ m

I've found American eBay is also good source of more Eaton bits,

Carolyn · August 16, 2016, 13:20

That's handy. Thank you.

Blue al · September 5, 2016, 23:29

Might be a bit of inspiration

M45 charger

1.6 ltr engine

shnazzle · September 19, 2016, 14:01

How's this looking? Or has work stopped temporarily in favour of life? s:)

s:)

Carolyn · September 19, 2016, 15:32

David's making a selection of pulleys... It's plodding along. I've got an engine swap to do to free up another engine for the project. The one we've been using is going back in my car, and I'm not doing that until the weather gets a bit worse, and I can bear to take my car off the road...
When something important happens, you'll hear about it!

Carolyn · September 22, 2016, 08:46

Not really 'important', just a little progress to report....

jvanzyl · September 22, 2016, 09:06

Hooray! Progress!! :-) :-) :-)

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shnazzle · September 22, 2016, 09:48

I think that classes as important on this build s:)

s:)

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Carolyn · September 24, 2016, 11:12

Well, the physical mounting and line-up is now done. Note the extra idler to clear the tensioner.

shnazzle · September 24, 2016, 12:43

Looking good!

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Mikeymead · September 24, 2016, 12:58

Quote from: "shnazzle"Looking good!

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+1, very neat.

Carolyn · September 25, 2016, 16:35

Well , took the back off the blue car this morning and started a 'trial fit'. So much for all the pre-measuring. It fits with no chopping to the sub-frame!!! The exhaust is going to be a bit trick, and one of the diagonal sheet-metal struts has to go.... but it's looking a much simpler job than I thought.

MR2j · September 25, 2016, 18:38

That looks awesome! Really impressive

jvanzyl · September 25, 2016, 22:36

AAARGH!! I can't wait for this thing to work!!!
Rebuilt 1zz plus this will be totally on the cards for a lot of people I think!!

Blue al · September 26, 2016, 15:08

As the metalwork side of things has gone so well, so far
are you in a position to fire it up soon, have injectors and management been lined up,
I have back-tracked and cannot see a conclusion for the next step ?
I have some stock mini injectors/fuel rail if it helps (good for 230 bhp)

jvanzyl · September 26, 2016, 15:24

Is there an up to date check list of what components are still needed for this project?
If there is one thing I can do is trawl eBay- but I need specific instructions!

Carolyn · September 26, 2016, 15:45

Quote from: "Blue al"As the metalwork side of things has gone so well, so far
are you in a position to fire it up soon, have injectors and management been lined up,
I have back-tracked and cannot see a conclusion for the next step ?
I have some stock mini injectors/fuel rail if it helps (good for 230 bhp)

The long answer is.... nope.

The plan is to fire it up as stock as possible (with a boost gauge) and use a reader to have a look at what it's actually doing. I'm thinking 2ZZ injectors... management has most certainly not been lined up. With a around 5lbs of boost (that's the target) we should be pretty good with the compression ratio. (done a bit of research on that one and the consensus seems to be we shouldn't have to play with timing to avoid detonation). A small intercooler looks like the way to go..

The biggest obstacle to firing up is building the exhaust. That is pretty much a custom job from one end to the other.

Could use an aftermarket cat and a small silencer...

Blue al · September 26, 2016, 16:42

With studs, and drill, could you fit a stock manifold upside down
Some straps and bungee sees the rest of the system hanging from the roof

All in the interests of "bench testing", (don't drive anywhere s:lol: :lol: s:lol: )

Seems a shame to throw the cost of a full custom system at it, so early in the development process

Carolyn · September 26, 2016, 16:55

Not much cost - we're fabricating most of it. Took the heat-shields off a standard cat (big ugly lumpy thing) and we'll chop it about to get it to fit. Then some kind of silencer (possibly motorbike...we've got a few of those). We've already chopped a Toyosport (used one) and we're extending it, with straight stainless tube)over the top of the supercharger to deliver the other side of the anti-roll bar. Got to have somewhere for the Lambdas. If it's ever going to be reproduce-able we've got to come up with a workable exhaust. Plus we're trying to use the original airbox and MAF (it's hard to beat). Flexible ducting on the way for outlet.... going to try to leave the throttle-body where it is and use a mini bypass valve.
It's one of those things where you've got to assume it's going to work (at some point).
Dammit -I'm already donating a perfectly good working car to the project.

Edit; can't flip the manifold. Stud pattern.

Carolyn · October 7, 2016, 12:15

Well, it will do for testing and development... I'll have to have word with Hamish, when he gets finished moving shop, and see if we can't come up with something a little more elegant.

ChrisGB · October 7, 2016, 13:07

Quote from: "Carolyn"

s:lol: :lol: s:lol: love it!

jvanzyl · October 7, 2016, 13:59

Awesome :-) :-) :-)

In terms of a more "elegant" solution - I'm assuming cost wise it's cheaper to create some kind of manifold that would still meet up with the location of the standard downpipe/ cat? (if that's even possible??)

As if it doesn't then I'm guessing you're into custom cat fabrication as well then...

EDIT: Scratch that - just saw the higher up photo with the clearance!... guess it's custom manifold + Cat section & backbox?

Carolyn · October 7, 2016, 14:40

Quote from: "jvanzyl"Awesome :-) :-) :-)

In terms of a more "elegant" solution - I'm assuming cost wise it's cheaper to create some kind of manifold that would still meet up with the location of the standard downpipe/ cat? (if that's even possible??)

As if it doesn't then I'm guessing you're into custom cat fabrication as well then...

EDIT: Scratch that - just saw the higher up photo with the clearance!... guess it's custom manifold + Cat section & backbox?

That'll be the one. Motorbike silencer, methinks. Custom all the way, though we might do a lash-up to get her running.

jvanzyl · October 7, 2016, 14:50

In terms of just getting running - couldn't you just pop the standard cat and backbox on? (no idea how you'd support it)

Also - in terms of engine management. Where are you at? I've just taken delivery of Lee's eManage Blue, I won't be fitting it for a month or two due to other commitments. So if that would help, I can loan it to you?