Robs new project Supercharger

[Rob Furniss]

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.

Shane I think you're over-reacting a bit, what i've done is change the route that the fluid takes from the reservoir to the master cylinder and I think it's pretty safe, i've spent countless hours looking into the correct hose and trying to source it. A lot of people told me to use fuel hose but I knew this to be the wrong stuff so I got the proper hose shipped from abroad. I'm certainly not putting anyone at risk - this part of the system is low pressure.

Maybe it could be done better and i'm going to look into improving it as i've already said. I did speak to a brake specialist last week and told him what I was planning and he advised me what to use, I think I will take my car round and see what he suggests just to make sure it's safe and ask his advice on improvements just to be on the safe side.

[Shane001]

Yeah possibly, I just see people messing with brake systems and get real nervous lol.

Good that you're getting specialist advice. Also probably good that you did start with clear hose as this shows up the problem of air in the system, which you don't want, even though this part of the brake system is low pressure. And really the cable ties have got to go

A suggestion. Maybe find one of the european cars that do have relocated master cylinders and use some of their bits?

[Rob Furniss]

Yeah possibly, I just see people messing with brake systems and get real nervous lol.

Good that you're getting specialist advice. Also probably good that you did start with clear hose as this shows up the problem of air in the system, which you don't want, even though this part of the brake system is low pressure. And really the cable ties have got to go

A suggestion. Maybe find one of the european cars that do have relocated master cylinders and use some of their bits?

Yeah that's a good idea, will see what eurotrash I can find.
Those cable ties do look dodgy I must admit, think I will make an ally bracket if I can't find something.

[Astron_Boy]

Yeah, good thought on using salvage parts.
Got to a pick-a-part place and that way you could visually inspect.

From memory on 90% of the instances where a remote resevoir was used, it was well away from anything else mechanical.
A lot of the time, the entire master cylinder and resevoir were sanctioned off, between the engine and the firewall, in it's own little cubby hole.
The Mercs do a similar thing, though unsure of their earlier examples.

Is there not enough room to mount it higher, above the cylinder?
Where the compliance/ chassis plates are?
May be a safer spot and more efficient.

I will also state simply for clarification, I am also not a brake specialist or any sort of mechanical engineer, take what I say as a grain of salt.

[Rob Furniss]

I've found this info, it's Vehicle standard Australian Design Rule 42/04 - general safety

Section 15 - BRAKE TUBING AND BRAKE HOSE

Flexible hydraulic brake hoses, air or vacuum brake tubing and air and vacuum hose, flexible and hydraulic power hose between the ‘Brake Power Unit 31/00’ or ‘Brake Power Unit 35/00’ and the master cylinder or its equivalent must conform to SAA, SAE, BS, JIS, DIN, ISO or ECE Standards, or FMVSS 106 Brake Hoses, specified for flexible brake hoses, air brake tubing or hose or vacuum brake tubing or hose or hydraulic power tubing or hose and be fitted to the vehicle as to prevent chafing, kinking or other mechanical damage under normal motion of the parts to which they are attached.

The new hose that arrived today is EPDM rubber which I know is the correct compound, it also has SAE J20R3 stamped on it which I knew before I bought it, i'm going to keep the clear on until i'm settled on the final position of the reservoir as I may move it and like Shane said the clear tube has been helpful to see air in the tube which isn't good.
I now plan on doing the following:
a) move the reservoir so that it's sufficiently higher than the master cylinder to provide a better gravity feed of fluid.
b) secure the pushfit connectors into the master cylinder better instead of relying on their tightness and cable ties (may need to make some kind of bracket).
c) use more elbows to eliminate kinking
d) swap the hose to my new EPDM SAE J20R3 hose
e) secure the hose to the body using clips so that it's not moving around and chaffing on anything
f) may need to move the hose entirly so that nothing that breaks (belt etc) can take the hose out or shield it

I'm still going to let the brake specialist have a butchers too.

Shane - thanks for giving me a check on this, now i've typed the above I can see at a glance that i've not done enough on this.

[Shane001]

Shane - thanks for giving me a check on this, now i've typed the above I can see at a glance that i've not done enough on this.

hehe, no worries anytime Rob

But you're right I probably did overreact a little, but I think the end result is looking better

[Rob Furniss]

Just cut out the charger front mounting bracket from some 10mm ally plate, still a little rough but you get the picture

It's going to sit above the rear cam cover

[Astron_Boy]

Looks good.

[aza013]

It's progressing well mate .

[Rob Furniss]

I'm not going to use the hole at the bottom right as it would only be going into really thin ally, going to brace it elsewhere and currently working on that.

[Taz]

Looking good mate.

Point of note i would hate for something to go wrong with the timing belt or something similar, looks like its going to be a real c**t to get to with all this extra stuff being put in the way

[Rob Furniss]

Looking good mate.

Point of note i would hate for something to go wrong with the timing belt or something similar, looks like its going to be a real c**t to get to with all this extra stuff being put in the way

You should have seen my last supercharger setup, that took hours to remove which is why i'm changing the brackets so they can be removed a lot quicker, really i'm probably adding about 30 mins to an hour onto a cambelt change - maybe less.
EDIT: Lets wait until i've finished, may end up being a spiders web of brackets and braces

[Supplanter]

Just cut out the charger front mounting bracket from some 10mm ally plate, still a little rough but you get the picture

It's going to sit above the rear cam cover

Nice safety shoes.

[Bennoz]

Aus spec steel cap thongs

[Astron_Boy]

Come on Rob, hurry up!

http://www.youtube.com/watch?v=I7A1chVy ... re=related

[Rob Furniss]

Ah yes, nice bit of inspiration, I shall get cracking straight away!

[Astron_Boy]

If you get this one sounding as good as your original it will be sweet indeed.
That sound is 2nd to a big honking v8-12.

[AJ]

Sorry, I just have to ask...

Who fuckin' drags in a Ford Ka?





Hope you gave the drive a bitch slap and sent them home.

[Rob Furniss]

Just, it was a turbo'd Ka.

I think I was only on 5psi boost then.

[Rob Furniss]

I need the charger in exactly the right place now so I can finalise brackets and the way I do this is clamp a flat bar between the end of the supercharger pulley and alternator pulley, problem is I didn't have the double pulley fitted so after lots of swearing:

Pulley came off really easy, and actually the alternator came out pretty easy too, it's just a faf having to undo so much.







Started first time afterwards (phew!)