Robs new project Supercharger

[Shane001]

Down to only 2 rods (again) and I only received these the other day, also on my 5th bottle of mapp gas, looks like it would have been cheaper for a pro to do it.

Yeah I was thinking that as well but didn't want to say. Hindsight is a wonderful thing isn't it

[Rob Furniss]

I've managed to seal the leak inside one of the air end tanks - using metal epoxy (I know but I believe this is a feasible and not to crazy solution). Water used to leak into hear from the water end tank but not any more so this stuff does work really well and has great properties too (great bonding and temp rating above 100C).
I'm going to remove the blanking plate from the water end tank again and seal inside with this epoxy, then going to use epoxy on the other side which isn't even attached yet.

The brazing rods are doing a great job at holding the whole thing together and I can tell you it's quite solid, in fact the brazing material is harder than the ally, just not great at making an air/water tight seal where the material is attaching to the core - I think because of the core's heat sink properties I just can't get enough heat in to penetrate so it's more like i'ts sticking to it.

I know I should have given up by now and gone to a pro but I want to see this through and having one last try, I think my solution of using some epoxy to help in the sealing process isn't a bad one either. So i've just bought my 6th bottle of mapp gas and ordered another 10 rods (yeah yeah I know it would have by now been cheaper to use a pro!).
Also what about enamel painting the whole thing after - would this work as well as powder coating for any pin holes that I miss?

[Rob Furniss]

Plenum/charge cooler is now pretty much done, just need to tidy it up and braze the intake pipe on which i'm waiting for.
I've ended up with a combination of brazing to keep it all together - and it is strong, and metal epoxy to seal it (the epoxy is for aluminium and other metals).

After tidying it up I can do a test fit and get working on the charger mounting bracket which may be a different design to what I used last time to make the fitting process easier (ended up being a good strong bracket but almost impossible to fit due to access).
I may even attach the charger outlet flange to the charge cooler (thanks for the idea clinet) but I think it would need extra bracing to make it strong enough rather than just brazing a 1.6mm wall 3" ally intake pipe between the flange and CC (one of my thoughts - not a good one).
I really want to end up with a more generic mounting option to in case someone else wants a bracket but doesn't want to go down the route of a charge cooler integrated into the plenum.

If I could have some kind of cradle that bolts to the engine integrated with the outlet flange then that would be great as it leaves plenum options open but puts the charger in the correct position. Problem is spare bolt holes on the engine in good places (around the V or over the rear rocker).
Worse case I just go with what I know and bolt a plate to the rear of the rear bank and then bolt the charger to that.

Emanage is on it's way.
Need to order some other bits for the charge cooler setup like a remote filler cap, small rad and a pump
Also DT Bypass valve, and some 275cc injectors but other than that I don't need a lot more.

As for when i'm going to fit it - well I need to change the plugs (no biggy) and cambelt first (not looking forward to that!)

[Astron_Boy]

Atleast you've made some progress.

[Rob Furniss]

Atleast you've made some progress.

Not really the way I wanted all this to go but I think the solution is ok.
The intake manifold on one of my cars was some sort of plastic so I think ally with epoxy isn't so bad after all.

[Bennoz]

What was the epoxy you used? Is it Devcon? If so, then that'll be stronger than half the manifold, I love that stuff!

I've used it to block a crack between cylinders!

[Rob Furniss]

No it's not Devcon, some selleys product for metal I think but i've just looked up Devcon and it looks good, I may get some of that and neatly apply it around the outside seams just as extra protection.
How hot is my charge cooler going to get, won't be anywhere near 100 degrees C will it?
Or I may take off my water end tanks and re-do with this Devcon stuff, that's the only place where I previously found leaks.

[clint111]

Shouldn't.
Maybe 60 to 70?

[Rob Furniss]

Shouldn't.
Maybe 60 to 70?

Ok that's well withing limits of Devcon and the epoxy that i've currently used, thanks Clint.

[Rob Furniss]

Here's the latest pics:

[Rob Furniss]

Look what just arrived:

Emanage blue, 2nd hand and has a few battle scars but only cost me $260 delivered including main, ignition and injector harnesses.

[Rob Furniss]

Remote mounted the brake reservoir yesterday to clear the supercharger pulley.
Here's a couple of pics, not in it's final position as I think I need to raise it a little to get more gravity feed and also i'm waiting on EPDM rubber hoses arriving from the UK as these clear plastic ones are a bit crap and kink too easily but I had to get the reservoir out of the way so that I can get on with making the mounting brackets for the charger - too difficult to measure up with it in the way.




Hoping to get on with making the mounting brackets in the next few days, will hopefully have some pics up next week.

[Astron_Boy]

So that's why you wanted that hose.
I could not for the life of me figure out what you were going to do with it.

[Rob Furniss]

Lol, well the epdm hose arrived this morning but haven't had a chance to swap the clear stuff out for the epdm yet, also a bit concerned why the tubing isn't full of brake fluid even though i've filled the reservoir - bleeding required or raise the height of the reservoir?.

A bit more progress:
Test fitting so I can make sure things fit and work out how to do the brackets as I want to do them different (= easier and quicker to fit than last time).





which side looks best?




The bracket will be joined to a bar running along the back of the engine where the standard plenum rear brackets are giving it some lateral bracing (i'm trying to keep the standard brackets if I can to make things simpler). I'm also going to try to brace it at the front edge too.
I've just scribed the template onto some 10mm thick ally plate ready to cut out - that's a job for later though.

[Astron_Boy]

Don't really know enough about brake systems.
My thought is they were all pressurised, so shouldn't matter about gravity feed... could be wrong.

placement and fit looks alright.

[Shane001]

Sorry Rob, but someone needs to ask this, is this going to be a street vehicle or track vehicle only?
If street vehicle, are you planning to get any engineering certs for the work you're doing?

I'm going to be completely honest, that brake master cylinder relocation is dodgy as imo. Either don't do it or have it done properly and certified. If you're brakes fail on the street it's not just you that may die.

[Rob Furniss]

Sorry Rob, but someone needs to ask this, is this going to be a street vehicle or track vehicle only?
If street vehicle, are you planning to get any engineering certs for the work you're doing?

I'm going to be completely honest, that brake master cylinder relocation is dodgy as imo. Either don't do it or have it done properly and certified. If you're brakes fail on the street it's not just you that may die.

No worries for asking Shane and it's intended to be a street car and yes i'm planning on getting engineering certs.
I did the same relocation in the UK and it passed it's MOT year after year.
I don't see how the brakes could fail due to a remote brake reservoir though, this is factory on some vehicles or is it just the way that i've done it?

Ok maybe the cable ties on the push fit elbows doesn't look great and maybe I could make a proper clamp/bracket to secure those or is there something even more dodgy that you've spotted?

I'm open to suggestions as to how I could improve things and appreciate your input/concern.

[Astron_Boy]

couldn't tell you how to fix it, but yes, a remote resevoir is factory on a lot of euro cars.
The likes of Lancia, fiat and vw adapted it for quite some time.
BMW did it during the 70s and probably prior, and volvo also had the odd remote resevoir.

It's not really clear visually how you've done it, but perhaps using steel angle pieces would be more appropriate than having the hose kink and do an S bend from where it is now stationed.

I think worse case scenario really is if the accesory belt snaps, flys, takes out the hose to which you lose both engine power and braking...
Agasin, worse case and simply thinking aloud.

[Rob Furniss]

couldn't tell you how to fix it, but yes, a remote resevoir is factory on a lot of euro cars.
The likes of Lancia, fiat and vw adapted it for quite some time.
BMW did it during the 70s and probably prior, and volvo also had the odd remote resevoir.

It's not really clear visually how you've done it, but perhaps using steel angle pieces would be more appropriate than having the hose kink and do an S bend from where it is now stationed.

I think worse case scenario really is if the accesory belt snaps, flys, takes out the hose to which you lose both engine power and braking...
Agasin, worse case and simply thinking aloud.

Jaguar too I think.

Good point mate, i'm sure I can improve on how i've done it and first thing is I will pick up some elbows tomorrow like you suggested, this new EPDM hose that i've got is also less kinky too.
I thought the reservoir was just there to take up the slack when your brake pads get low though, if I removed my new connectors from the master cylinder the brakes would still work (although i'm not going to try it).
I may also see if I can move it onto the firewall so well away from anything but I think I looked at that once and there's no room, would need a slimline/long reservoir from somewhere like willwoods or ap.

[Shane001]

I'm not a brake engineer so I'm not going to begin to suggest how this should be done, but you've also suggested that you don't know how to do this either and that you're not sure if what you have done is right or not.

Speaking to a brake system engineer or spending the time to research and learn how this should be done would be a good idea I think. I'd be very surprised if what you've done there would pass an inspection here in Australia.

Messing with things like brake systems when you don't understand what you're doing is potentially playing russian roulette with other peoples lives.