Was a Paxton supercharger conversion, now a Rotrex C38-91

r2d2hp · Post by **r2d2hp** » Mon Jan 31, 2011 12:00 am

Not sure what room you have in the Mk3 Tony but now way I could fit anything like that in Mk1. My IC is much smaller and trying to get pipes round the side of the rad was not easy.

The other problem I have is the restriction in airflow due the IC and the small grill area. When standing still my temps are up at over 100 C even with 2 fans running.

Be interested to know what solution you come up with

Post by **Coops** » Mon Jan 31, 2011 12:05 am

will have to cut quite a bit of the front out for that mate

anything smaller length wise we could use ????
i dont think im going to be around 600bhp from my setup some how

Post by **Coops** » Mon Jan 31, 2011 12:07 am

r2d2hp wrote:Not sure what room you have in the Mk3 Tony but now way I could fit anything like that in Mk1. My IC is much smaller and trying to get pipes round the side of the rad was not easy.

The other problem I have is the restriction in airflow due the IC and the small grill area. When standing still my temps are up at over 100 C even with 2 fans running.

Be interested to know what solution you come up with

what intercooler you got Reg?

r2d2hp · Post by **r2d2hp** » Mon Jan 31, 2011 12:42 am

Think its this one Tony >> Deep Core ..450 Series.. Intercooler, 76mm ( 3" ) Aluminum Hose Joiner

from here >>

http://cgi.ebay.co.uk/Performance-Inter ... 3360f9fa81

Not sure its doing much really as its quite small. Be interested if you are able to fit something larger

stevieturbo · Post by **stevieturbo** » Mon Jan 31, 2011 8:57 am

Coops wrote:will have to cut quite a bit of the front out for that mate

anything smaller length wise we could use ????
i dont think im going to be around 600bhp from my setup some how

Dont believe for one second the numbers those places quote. In fact, anywhere that uses numbers like that for rating an intercooler are on drugs.

To just say an IC is good for say 500bhp is just nonsense.

A 5.0 V8 with a blower making 500bhp will have massively different IC requirements to a 1.0 making 500bhp due to the heat involved
Airflow may be similar, but cooling requirements wont.

If you are space limited ( angle grinder works wonders ) then just opt for the biggest you can.

But cutting and welding OE Cossie cores together is quite common, and wont end up too big.
Either stacked on top of each other. Or Ive seen 2 on top, and wit another in front as well. So 3 cores in total.
Obviously putting them in front of each other will reduce their efficiency, but overall it will still help, especially in terms of airflow through the IC for the engine itself.

Dont forget though, you dont have to mount sideways, any cores can go top/bottom too if that helps space.

But with an angle grinder, there should be tons of room up front ! A Capri bonnet engine bay is a lot bigger than mine, and my IC is pretty damn big !!

If you wanted, I could sell my old Pace cores, although you'd need to fab end tanks.

I think they were something like 11x12" or so each
I still wouldnt say they are fantastic though, but size wise they may suit better ?
Will stick a pic up later.

Post by **Coops** » Sun Apr 01, 2012 8:09 pm

time this got updated

Take a lump of 5" ally bar, and a lathe, and you get the following.....

charger pulley taking shape:

after many many hours and late nights, you get this

And all bolted up to the charger complete with new dip stick,

next on the list... how thick steel should i use for the mounting plates for the charger? 10mm? 12mm? 15mm?

stevieturbo · Post by **stevieturbo** » Sun Apr 01, 2012 9:20 pm

Ideally the pulley needs hard anodised to protect it. Although I think the large diameter should save it as the belt shouldnt really be doing too much work.

As for steel etc. Depends really. How big, how many securing bolts, where they are, what room is there for the bracket to flex ?

Again the large pulley diameter will help as you shouldnt need as much tension to actually make the belt work

Other than cost/machining there are no downsides to using thicker steel ( or aluminium as required ) other than weight too I guess.

Post by **Coops** » Sun Apr 01, 2012 9:59 pm

there is a plate that bolts to the three bolt holes on the front of the head, then theres tubes bolted through to the bracket on the charger, was thinking of putting an adjustable link rod fron the charger back to the engine to to stop any whip.

kiwicar · Post by **kiwicar** » Mon Apr 02, 2012 10:03 am

Hi Tony, I'd make those plates out of 4 to 6mm ally, steel would be overkill, unless you made it in 1.5mm steel and "boxed" all the edges. I would think 5mm ally would be ideal, with the bulk of the supercharger to stiffen everything and the tubes around the bolts it will be pretty rigid. I do rather like the plywood aproach, it has a certain charm.
Best regards
Mike

stevieturbo · Post by **stevieturbo** » Mon Apr 02, 2012 3:48 pm

The front one could be thin ok. But the one that bolts to the block needs to be strong. It will surprise you how much they can flex when you tension a belt. Mines 15mm steel and the flex is clearly visible. The length of blower from any actual fixing points etc acts as a big lever.

Post by **Coops** » Tue Apr 03, 2012 12:45 pm

so in steel, 15mm to bolt to block, 10mm the blower bolts too?

who was it on the forum that did water jetting?

stevieturbo · Post by **stevieturbo** » Tue Apr 03, 2012 1:26 pm

Front would be fine in 6 to 8mm.

Main bracket could be fine in 12, just depends if you can use 15mm there is no harm in over engineering

Ralph85 can sort the bracket.

Post by **Coops** » Tue Apr 03, 2012 2:25 pm

well the main bracket and blower bracket are in 3/4 (19mm) ply, so if its ok to go smaller i can do it,

15mm main bracket is fine by me, if your sure 8mm is fine in steel for the blower bracket then i'll finish it off and get them sent off,

im thinking of putting some sort of rose jointed brace from the blower bracket back to the block or water pump somewhere,

Ralphh85 · Post by **Ralphh85** » Tue Apr 03, 2012 3:07 pm

nice looking blower!

you lot an your overkill

Ralph

Post by **Coops** » Tue Apr 03, 2012 3:16 pm

hi mate good to hear from you,

what would you recommend?