Cts Supercharger

[nrgizerbunny]

I'll take some pictures when i can be bothered, its friday night and i'm pooped!

[nrgizerbunny]

I'll take some pictures when i can be bothered, its friday night and i'm pooped!

[215 compressor]

OKay the blow off valve is here, as far as I can tell it looks legit. the packaging is too good to be fake but being the curious git that I am, I'm going to take it apart to have a look at it.

the need for the bov comes from when caning the car, if you cane it and lets say get to 8000RPM then lift the throttle, the valve will be shut and you will be compressing air against a shut valve. You'll generate a whole load of boost and cause backpressure which will trash the bearings in the supercharger.

My setup is like this:

Air enters air filter

Through Supercharger

Through intercooler

Through Blow off Valve

Through MAF sensor

Through throttle valve

on the compressor its set up different it goes air filter ,maff air ,throttle valve supercharger,intercooler then engine .

don,t no if will make any difference on your set up but you won,t get the pressure build at the throttle side so no need for the bov but will make a nice sound on gear changes.

[nrgizerbunny]

correct me if i'm wrong but I didn't think the compressor had an intercooler.

The maf sensor position determines if you have a recirculating bov or not, on the Compressor the air that goes into the blower is metered so the ECU accounts for it, if you then bleed that to atmosphere you get a rich mix and the car will be hesitant.

I didn't buy the BOV for the sound, I bought it out of necessity and on Clawligers recommendation! LOL

[Clawliger]

But the noise is sexual lol. Have you listened to them on youtube?

And yes the conpressor has no intercooler. And the charger is integrated into the inlet manifold so its a different set up all together.

[illgryphon]

Good work on the build, all this dumping of air is slightly confusing though. Was going to say the comp doesn't have a bov valve, because i don't get any sweet noises :o

215 installed the smaller pulley, and intercooler etc

[nrgizerbunny]

I'll draw a diagram to show the difference!

[nrgizerbunny]

superchargerschematic.pdf

Okay, I've drawn a diagram, I hope it makes sense! its attached.

[215 compressor]

had a look at your diagram and the corolla compressor set up isn,t as per the diagram and there is no by pass valve that i am aware of .air goes in from air filter then mass air then through throttle valve and straight to supercharger then from supercharger into inlet manifold .only thing on mine is ive fitted an intercooler in and smaller pulley and piggy back ecu and remap but kept the route the air travels the same .should of mentioned on my post had fitted an intercooler.

[nrgizerbunny]

I have been a lazy swine watched rugby and forgotten to take bov pictures.

In the intervening period, to make sure my bracket could take the load, I did a finite element analysis on it. These photos looks bad and red is worse but to put it into perspective if I hang 30kg off the end of it, the bracket will flex 0.0005mm, a five pound note is 0.1mm thick. So to the techie folk out there, here's the loadings

here's the stress distribution magnified by about 5000

and finally here's the displacement magnified by about 5000

[LOZZA_T_SPORT]

Loving the technical pics, these are right up my street, geeky I know but I dont care

[nrgizerbunny]

I don't know if anyone is actually reading this or if i'm talking to the baron internet but nonetheless here's an update.

Firstly BOV, i've come to the conclusion its legit. i've seen the knock offs and the engineering is too precise for it to be knocked off, also the tell tale circlips seem to be of good quality.

My idler pulley, I made up a spacer for it and then pushed it in, its not an interference fit but requires a hammer blow to get it out. For info the pulley is from a landrover. It was a bit of F*****ER to get the alignment and rocking sorted but i got it in the end.

Here's the inlet restrictor should I need it.

The rad is getting angled slightly forward so I needed to make some new spacers. I made them slightly too long so I'll get a bit nobbled off to fit. I had a fair idea what would fit but its not perfect until you get it on the vehicle. I used a rubber grommet that goes in the back of electrical socket boxes to act as my vibration dampener, I made a slight recess on top of the spacer so it wouldn't wobble.

[pimp1chez]

I have been a lazy swine watched rugby and forgotten to take bov pictures.

In the intervening period, to make sure my bracket could take the load, I did a finite element analysis on it. These photos looks bad and red is worse but to put it into perspective if I hang 30kg off the end of it, the bracket will flex 0.0005mm, a five pound note is 0.1mm thick. So to the techie folk out there, here's the loadings

here's the stress distribution magnified by about 5000

and finally here's the displacement magnified by about 5000

oo good old solidworks ,this project is nuts man keep up the good work

[sheepscloth]

Brilliant work

Rotrex is just around the corner from me so I am following this with great interest!

Well done!

[FoxX]

Where abouts are you mounting your intercooler bunny?

Is it going to be a similar-ish setup to this HG-motorsport one for the CTSC ? which is infront on the main radiator, the gap looks big enough looking at some bumper off pictures.

Tad on the expensive side that intercooler!

[nrgizerbunny]

yep i'm mounting it like that intercooler,

I'm just having both inlet and outlet on one side. I don't know how they routed that pipe on the driver side into the engine bay without chopping some metal out.

[nrgizerbunny]

My intercooler has turned up! Obviously I bought the BIGGEST that would fit!

[nrgizerbunny]

intercooler positioned, F*** me is it tight!

[215 compressor]

intercooler positioned, F*** me is it tight!

No what you mean was tight fitting mine in also had to contend with the oil cooler.keep up the good work.

[FoxX]

You have any piccies of your intercooler? sounds like a monster

[nrgizerbunny]

Here it is, 78mm core, 600 wide, 300 high.

I started off by putting it into position and lifted it with a trolley jack, Then I fabbed up some brackets and welded them to the bumper support. Sprayed all the welds up with galvanizing spray and then put it back together.

For some reason my cack camerawork makes this intercooler pic look like its not level, i can guarantee it is. I used a stabila spirit level to check it!

[nrgizerbunny]

oh well, i guess its piping next week!

[PaulinhoT]

I've just sat and read through this all, a very good thread, and a mighty looking project

Keep us updated

[215 compressor]

thats one large intercooler looks like the top pipe is heading straight to the mounting bracket will you have room to get your to pipes connected looks very close .i had alot of problems getting the piping routed right on mine so ended up using an intercooler mount with pipes inlet and outlet at either end and going through the left side near the air injection pump and by the radiator to connect the other side.be interested to see how you overcome the piping issues as space is a bit of a problem.

[nrgizerbunny]

i'm hoping i can rely on the ability of silicone to flex slightly!

I had a look on the internet and the guys in OZ and the USA tend to use much smaller intercoolers and mount them on the bottom of the bumper bar.

I'm not actually sure you need an intercooler for a supercharger but nonetheless other than the ballache factor it will be beneficial.