Mini supercharger on 1zz

[Carolyn]

I'll check on that, though Boxter fans with thermo are on fleabay to £25

[Carolyn]

Probably the biggest challenge has been to get the exhaust to fit with very limited space, and keeping ground clearance good.

Had to compromise with the junction beneath the plate, but this is what had to be done to get a decent cat in.

[shnazzle]

Ouch. Granted, the only way that collector is going to get any prettier is by casting. Or some very fancy cutting/welding.

[jvanzyl]

But hey... if it works, then I think the aesthetics will be worth enduring!  :-) :-) :-)  

What's next on the list of to do's??

[Carolyn]

It's a bit more then aesthetics, I'm afraid - not ideal flow.  Not disastrous though.

Weld up the rest of the exhaust, sort out the hangers.

Make and install heat shields.  Mount fan.  Make mounts for the airbox.

Install the emanage.

tune it up.

Won't be quick, it's bloody cold in the workshop even with the wood-burner going.  Can only take cold a bit at a time.
.

[shnazzle]

I was talking flow   s:) s:)  Don't give a monkeys about aesthetics! Not to exhaust parts anyway... Other than the tips  s:) s:)  

But you're right, it'll do for now  s:) s:)

[Carolyn]

Okay...
Getting close.  Time to put the emange in the car.  Simple plug-in, thank God.
Now.  Where to put it and how best to mount it?
Harness leads about 4' long, so plenty of scope.  (Can also be coiled up).
I'm thinking passenger foot well....

[shnazzle]

I just have mine in the passenger rear bin. Easy access for the laptop cable and front dials

[Carolyn]

How have you secured it?  Have you done anything to protect from shocks?

[shnazzle]

Yes I put a bit of foam and then under the straps that are in the bin. Holds it in place nicely.

[jvanzyl]

Pardon the utter naivety in this area.. but I'd love to see a pic or two of the actual installation process.. I'm dead paranoid on getting this wrong and at my current rate of progress it's only looking to get installed at Ding day 2017!

[Carolyn]

I seem to recall that you have a plug and play harness, which makes it a doddle.  You just unplug the ECU and car connections behind the luggage bin, plug  in your new harness to the stuff coming from the engine, plug your Emanage into the harness and plug the harness back into the ECU and car.  The connectors can only go in one way.
I'm using a harness extension, so I've had to solder in connectors to the extension and and connect my Emanage harnesses to it.  A lot more work and very fiddly.
Here's what I've now got (big connector takes the stuff from the engine, bottom ones go to ECU and car):

[shnazzle]

To get to that point....
In the passenger bin:
- Remove bin door (two screws)
- Remove plastic on the right side of the bin (one pull-tab at the top and pull out)
- Remove bin liner (two screws on the bottom). You'll have to open the driver's bin door to wriggle it out.
- push aside the access flap you see at the back
- Undo the security bolt on the big black bracket (Forgot the size. It's a hollow-tip torx. Size 6 maybe?)
- Move bracket aside and unplug cables from ECU
- Plug those cables into the harness. Only one way
- Plug the harness into the stock ECU
- Plug the other end into the emanage.
- Put everything back (I didn't bother with the security bolt. Just used another nromal bolt)
- Remove battery neg cable for 20 mins to reset ECU.
Sorted.

[jvanzyl]

Thanks both! That does help! And once it's all plugged in I plug in the laptop, and then turn the key on the ignition so there is power but not actually turning the engine over and upload the right map?

[Carolyn]

That's the idea.  With a bit if ingenuity, you can get power to the Emanage and do the uploading out of the car.. but not needed.

[jvanzyl]

So then it's just a question of praying that the map uploaded doesn't detonate the engine  :-) :-) :-) ... I THINK what I might do is just start with a clean stock map to make sure everything still works before I start "adding" to it.

[Carolyn]

Let's start another thread for you project?
There are others who can advise better than I.

[shnazzle]

haha. That's polite for "stop thread-jacking John!"

But this same thing does apply to this build. What's the plan Carolyn? Are you going to use a base map of some sort or are you just going to put the injector compensation in and then go from there with zero'd tables?

[Carolyn]

I have a map that was designed for my layout (Maf, Throttle body position) for a Turbo with very similar boost.  I'm going to knock it back in the lower ranges (with it being a charger that will come in sooner).
I've got the right injectors so I might just richen it a tad all the way through.  The timing is pretty conservative on this map, but I will knock it back a bit in the lower ranges and make sure it runs knock-free.
Then it will be a dyno job.

[lamcote]

Good luck, hope it all works out.

[Carolyn]

I'm confident that it will work.  I'm just going to play it safe until I can get on the dyno.

Having gone though the process, I don't think it's a project for most Roadster owners.  Turbo is much easier to put together and much better understood.

Also it ain't cheap, especially if you can't do your own fabrication and machine work.

[Carolyn]

Update:
Exhaust fully fabricated.  Hangers still to do.  Emanage in.  Fan in and wired. Got to make mounts for airbox (which is now upside down, don't laugh it all lines up lovely).
To do: drain tank and put fresh fuel in.  Add boost guage for direct reading. Heat shield for airbox.  Cooler spark plugs to install.
Getting close.
Pics in a few days.

[lamcote]

I like the airbox idea.

[Carolyn]

We know the stock airbox and MAF are hard to improve upon, and the set-up works with turbos and 2zz.  I wanted to avoid the extra variable of a non-standard MAF mount.

[Essex2Visuvesi]

I hope the first start is going to be videod