Robs new project Supercharger

[Astron_Boy]

That how you did it before?
Just seems to me you'd be putting a fair bit of strain on the alternator.

Nice work however, looks pro.

[Rob Furniss]

That how you did it before?
Just seems to me you'd be putting a fair bit of strain on the alternator.

Nice work however, looks pro.

Yes mate and that was always something that bothered me so I conceded that the alternator would need a rebuild every now and then.
But the more I drove it the less I worried and I ran it like that for almost 2 years before selling it and coming here and never had a problem, this was my daily drive covering approx 170km's per day.

EDIT:Pulley was slightly different previously, had a 54mm inner diameter (4 rib alternator drive) and 51mm outer (6 rib charger drive), this one is 54mm diameter along the full length so it will spin the charger faster meaning I have more boost to play with (more choice of reduction pulleys to fit to the charger). Slightly less clearance against the chassis but it still clears enough to get the belt past. Will be less chance of the pulley catching on the chassis when I put new engine mounts in.

[Astron_Boy]

Yep, fair enough then, proven point.

It's a pity there isn't slightly more room between the crank and strut tower, probably would have made things easier.

I don't suppose there's anyway of running simply a larger belt and calculating the rotational requirement for the accessories attached to the back of the motor?
Probably more fiddling than needed, but just thinking out loud, and since you have experience, is good to have insight.

[Rob Furniss]

Longer alternator belt so there's no need for a double pulley? Yeah probably just need some idler pulleys and something to mount them to but that belt is a 4 rib and the charger pulley is a 6 rib so would have to get some kind of custom 4 rib charger pulley. There are some aftermarket 6 rib ones in different diameters (= different boost) for this charger. I didn't want to go smaller on the belt width/surface area but then again i'm relying on the alternator drive belt not slipping too so it's swings and roundabouts.

[Rob Furniss]

Been working on the charger mounting brackets as i'm doing it differently to last time so it will be much easier and quicker to fit/remove/re-fit, here's the progress so far:

[Astron_Boy]

Yah updates!
lol

Nice work, how far from the valve covers does the charger sit?

[Rob Furniss]

Yah updates!
lol

Nice work, how far from the valve covers does the charger sit?

Only a couple of mm.

[Rob Furniss]

Mounting bracket is almost finished:





That's using 2 mounting points, got at least another one to do/maybe 2 but I should now be able to bolt it on the engine and make sure the alignment is correct and also figure out where i'm going to mount the idler and tensioner pulley (trying to use one less than last time and also simplify the fitting procedure).

[Kustom]

Loving the updates rob keep them up !

[Rob Furniss]

Thought it was about time for an update, doesn't look much but i've made another two mounting points/brackets to bolt the charger to it's frame/bracket.
Also made an output flange - just need to cut a hole in it and weld my pipe on or I won't be going anywhere fast.

Next job is making a small pulley mounting bracket that will be attached to the front charger bracket at two or three points and also to the engine lifting point near the dipstick so this will also add more rigidity to the hole thing. The strength in all these brackets will be their collective strength rather than individual, makes it a bit trickier to make but the result will be good, there just aren't loads of places on our engine to bolt things to plus the charger mounting points are all over the place not just in one plane.

Anyway enough of my babbling, here's some pics.





BTW - for anyone attempting to cut ally plate with a jigsaw (which is pretty easy) I would recommend the Bosch fast cut blades, they are miles better than el cheapo/standard blades and cut through 5mm plate in no time, 10mm - a little longer but still better than my previous blades.

[bass_twitch]

Thought it was about time for an update, doesn't look much but i've made another two mounting points/brackets to bolt the charger to it's frame/bracket.
Also made an output flange - just need to cut a hole in it and weld my pipe on or I won't be going anywhere fast.

Next job is making a small pulley mounting bracket that will be attached to the front charger bracket at two or three points and also to the engine lifting point near the dipstick so this will also add more rigidity to the hole thing. The strength in all these brackets will be their collective strength rather than individual, makes it a bit trickier to make but the result will be good, there just aren't loads of places on our engine to bolt things to plus the charger mounting points are all over the place not just in one plane.

Anyway enough of my babbling, here's some pics.

This makes me Excited!!

[Rob Furniss]

Oh and i've won a Phenolic gasket on ebay, it replaces the metal one that sits between the intake manifold and plenum which will be plenum/charge cooler in my case, i'm hoping it will stop some of the heat transfer.



Waiting for this to arrive from the UK, ebay ad was by an FTOOC member who i've known for ages!

[Rob Furniss]

Didn't like where I had remoted the brake reservoir to so decided to move it well out of the way of everything and use the proper hose this time:



No problem with the bonnet closing, phew!

Also here's some pics of the finished charger mounting bracket, got to finish the small pulley bracket (it will bolt to the charger mounting bracket and then tensioner and idler pulleys will bolt to it) then i'm pretty much onto first fitting and checking alignment - and then seeing what i've forgot to do!
I still have to get a wideband afr sensor and gauge and wire in my emanage, oh and bigger injectors.

[Astron_Boy]

That's a pretty good spot for the resevoir!

Coming along nicely.

[Rob Furniss]

That's a pretty good spot for the resevoir!

Coming along nicely.

I really didn't think it would fit but I shoehorned it in, just seems such a better place for it - and it's higher up than before so a better gravity feed to the master cylinder?

[Astron_Boy]

Yeah, i'm not sure on the gravity feed effect for a pressurized system.
However I think you have some proven point when you had bubbles in the line with the temp clear hose...

[Rob Furniss]

Yeah, i'm not sure on the gravity feed effect for a pressurized system.
However I think you have some proven point when you had bubbles in the line with the temp clear hose...

I must say i've been for a short drive and the pedal feel seems better even though I haven't bleeded the brakes yet.

[I8A4RE]

UMMMMMMM.......................PRON!!

[Rob Furniss]

Just bought an AEM UEGO wideband AFR sensor/controller and gauge for $185 delivered, just need larger injectors and that's about the last of my spending for now (will still need a water pump and rad for the charge cooler but don't need that just yet).

[Astron_Boy]

Wooh, updates!

Can't wait to see it running!