A little supercharger project

[Carlitos]

Hi all... Thought I'd share a little project of mine. Might turn out good... might not. But the learning process is fun.

Decided to up the output from the supercharger. Managed to source a smaller pulley from Poland, a guy over there makes pulleys for various SC's. So the idea is that a smaller pulley on the supercharger means higher boost from the supercharger.This will mean the SC works harder (more rpm), more forced air (hotter) and higher SC rotor speeds particularly at high rpm (more hotter again).

So smaller pulley = more power. Great! But my concern is heat. The extra air means more friction and more heat. So to compensate I decided to port & polish the supercharger & inlet/outlet. Idea being the smooth it is the less air drag happens and less heat builds up. Hopefully compensating for the extra boost I'll be making.

I don't want to mess my own SC up so I bought one off ebay for £110. Bargain! You might be able to see in some of the early pictures how coarse the internal casting of the SC housing is. The more coarse, the more friction.. the more heat.

The SC without the inlet/outlet metal part


Size difference btweeen old & new pulley.


Started to port the inlet/outlet part




Let's get that old pulley off..... it's a bit tight!


Had to cut it and then heat it to removed even with the pulling kit. Was quite seized on. Although I should also say the new pulley was too loose. I contacted the chap in Poland who is sending another one out to me. So I'll continue with until that arrives.


Cut back the snout so the new pulley has more freedom to fit


Remove the screws. Note that the oil plug screw is damaged. I couldn't get that thing to budge and now it's worn down so decided to leave it how it is and change the oil later.


Needle bearing seem to be ok so have to sseal them off... don't want dirt getting int.


Oil... stinky


Back of snout


Porting in progress. I live in a flat so the safest place for me to do this is actually in the bathroom (I don't have outside areas to do this). Decent breathing filter and eye glasses are definitely required! Safety first. The tool I use is a rotary tool from Maplins, a cheap Dremmel. I have an extention and various tools, mostly sanding sleeves.


In progress but still not finished.

 

[AMGeed]

is this for the C200K Carl? Glad to see it's still running.
My old feller gave up driving last year.

 

[Carlitos]

Yep same little car. Thought about upgrading to a bigger engine model but decided just to have fun with this one for a bit longer.

From what you said before it's probably safer that your father has decided to stop driving. It's a big thing to give up though.

 

[DomCLK]

Nice one bud, are you going to block the silencer holes?

 

[Carlitos]

Was thinking about it but I don't really have the tools or materials to do so. The main purpose of the port is to reduce the extra heat build up cause by the smaller pulley/higher air flow.

The pulley I was going to fit was too loose. The kind chap in Poland sent me out a replacement which arrived today. Seems nice and tight but not fitted yet. Supercharger is currently in the freezer and will bake the pulley at about 200c hopefully tomorrow. Should assist in the fitting.

 

[Frontstep]

Can't beat a project, where would we be if people didn't have that odd urge to make things better or tinker.

 

[coventryslk]

Is it the m111 engine

 

[DomCLK]

https://www.youtube.com/watch?v=mhrLJAzwHlc

I love a wailing blower :grin::grin:

 

[Carlitos]

Is it the m111 engine

Yep, M111 2.0lt (m111.955 from memory). The supercharger is M45 non-clutched version.

 

[Carlitos]

For anybody interested here's some more progress on the little project.

So the first pulley was way to loose (hand loose) so I had a second one sent through. This one was nice and tight but a bit more of a pain to fit than I had hoped for. The idea was like a bearing. Freeze the supercharger and bake the pulley. The contracting and expanding should make it easier to fit. Well it did, to a degree. I then went for the next option. Using an M8 threaded rod, a few washers and a nut. This was working but half way on the rod snapped, sheared in half. Bit of a pain to get out of the SC shaft.

So ordered some high tensile rods & nuts (10.9 ones to be exact). Bought it from these guys http://www.orbitalfasteners.co.uk/ Really top service and good price. The rod came through taped to a long bit of wood so it was kept straight. It's the little things that impress.

Anyway, these top quality parts made a difference. Pulley fitted in minutes. If anybody plans to do this make sure you use high tensile screw parts! Even the one I used after probably shouldn't be used again due to the stress.


Hope made pusher. You can but something similar, perhaps a waterpump pusher or alternator. This was cheaper.


Screwed into the SC shaft.


Not pictured but I did have to use a pipe over the spanner to give more leverage


fitted.

 

[Carlitos]

Fitted! And what a difference! Can feel the extra power and it makes a really cool sound. The recirculation flap doesn't engage until I think around 2-3k revs and with the extra power that makes the extra power a bit delayed. I need to think how I can overcome this. I'm thinking a blanking plate to reduce the blow off from the flap or tweak the control software (if that's even possible)

I did have one problem when fitting. The inlet/outlet housing I worked on isn't actually the correct part! It's almost identical apart from the part which goes into the intercooler pipe. I've fitted the original non-ported one for now but will need to revisit that.

Will try to get some pictures up later. Might try for a video but that would be a job for tomorrow.

 

[Carlitos]

Old SC to come out


Slack off the belt by using a breaker bar on the tensioner. Then unscrew the SC.


Old and new


New one in place

 

[Carlitos]

Another little update for anybody interested.

This weekend I took of the original inlet/outlet part and port & polished that one. Refitted and complete. However I was pushing it hard up a dual carriage way today when I heard a loud pop noise and power loss, it was when the gearbox shifted up a gear at 7k revs. So under those conditions the SC would be outputting hard just when the throttle closes causing back pressure.

The pop sound was the pipe from the intercooler which plugs into the SC outlet, the pressure must have built up so hard that it popped the pipe off. I guess the blow-off/recirculation flap hadn't opened quick enough to vent off the excess air.

The connector is a bit rubbish. A tiny little clip is all that holds the pipes together so I’m going to look at something a bit more robust. I wonder if the added pressure & heat could do with an upgraded intercooler.

 

[star]

You might end up fixing all the weak spots on the charge pressure system. Great mod.

 

[Carlitos]

I think so. Stiill doing a biit of research but probably will go for a new intercooler with silicone hoses, aliminium tubing and all that.

But can't help thinking where does it end! Do I follow it up all the way to the inlet manifold? I'm guessing there's a way to fit a bigger throttle body from a v8 on it (although the stock manifold wouldn't support that).... but what after that! It probably never ends.

 

[Blueovalcraig]

Love it. Was thinking of doing this to mine one day