Forced Induction on a UK 1.6 on a budget ?

[Prince]

Give that company making the superchargers a call and ask if they could make you an intake manifold to go with their supercharger kit.





Apart from the intake manifold there isn't really a lot of stuff to get fabricated. The cost involved includes research and devlopment (which you'll do yourself mainly. The cost of the parts themselves would not equal the amount the kit costs.

I can list everything in the parts list for the DASC if it helps?

[Wanda]

Regarding the company call , do you mean Downing Atlanta or the UK company "GKD" ?
I was going to visit a local welder & hear his quotes on manifold fabrication...

Prince, I might ask for close up photos of your manifold, especially around pipe connections, so i get better ideas too.

I've got a PDF of the DASC parts (thanks to 318ti.org!) , so i have an idea of what to get... I might need your help in some situations lol..
------------

Anyways, i've decided not go with the turbo install & i'll order a S/C from Mercedes 230 as suggested (or mini's eaton m45 alternatively)

[Prince]

Originally Posted by Wanda

Regarding the company call , do you mean Downing Atlanta or the UK company "GKD" ?
I was going to visit a local welder & hear his quotes on manifold fabrication...

Prince, I might ask for close up photos of your manifold, especially around pipe connections, so i get better ideas too.

I've got a PDF of the DASC parts (thanks to 318ti.org!) , so i have an idea of what to get... I might need your help in some situations lol..
------------

Anyways, i've decided not go with the turbo install & i'll order a S/C from Mercedes 230 as suggested (or mini's eaton m45 alternatively)

GKD mate. DA are US based so the phonecall will cost a fortune, and Jim wasn't that helpful when I needed him. It was only thanks to Roy at CA the problem I had was sorted.

Here the pictures I took duting the install...













All the pictures I took are in my project thread on BFI as well mate. (BTW, are you playing this one close to your chest as you haven't mentioned it on BFI?)

[Wanda]

Prince thanks for the pictures, very very much appreciated!
I'll give GKD a call & see what's up.

I might need to find a way to get that valve on the manifold fabricated (I have to find that part anyway, not going to be easy)

I haven't mentioned on BFI because there isn't a section for Induction, and you & lee the only gurus with S/C on your cars...

I'll go over BFI & see some additional pics of your S/C build

[Prince]

Originally Posted by Wanda

Prince thanks for the pictures, very very much appreciated!
I'll give GKD a call & see what's up.

I might need to find a way to get that valve on the manifold fabricated (I have to find that part anyway, not going to be easy)

I haven't mentioned on BFI because there isn't a section for Induction, and you & lee the only gurus with S/C on your cars...

I'll go over BFI & see some additional pics of your S/C build

If it helps I can always take you out in mine one day so you can see for yourself what it's like. (Disco) Stu was very impressed with it when I took him out at Santa Pod. I'm based in Northampton.

[pdxmotorhead]

Originally Posted by Wanda

Prince thanks for the pictures, very very much appreciated!
I'll give GKD a call & see what's up.

I might need to find a way to get that valve on the manifold fabricated (I have to find that part anyway, not going to be easy)

I haven't mentioned on BFI because there isn't a section for Induction, and you & lee the only gurus with S/C on your cars...

I'll go over BFI & see some additional pics of your S/C build

That valve is the bypass valve ,,, its integrated with some models of eaton supercharger, A turbo charger bypass valve can be made to do the job, or eaton sells them, Look up http://www.magnacharger.com/ they are the hobbiest rep for Eaton in the US.

The bypass valve is open only under low power settings and is how they keep the mileage up.

The bypass valve is integrated in most of the GM affiliate units, Opel and I think Mini has it too.

Cheers
Dave

[Wanda]

I've just ordered the Merc 230 S/C , so awaiting delivery. It's probably an M45 since it's got an electromagnetic clutch (I might have to delete that anyway)

Is the turbo Blow Off Valve the same as Bypass Valve ? (different words but same thing ?)

[pdxmotorhead]

No a blow off valve releases pressure form teh intake system, a bypass valve allows air to get into the engine by going past the blower or turbo to the intake. A bypass valve opens under vacume and closes under boost.

One thing you could do with the electric clutch unit is set it up so you can flip a switch and disable boost. Handy if your unable to get good fuel or need to mellow the car out in icy weather and prevent wheel spin. Most eaton blowers share the front bolt pattern that holds the pulley on, you can buy a rebuilt non clutch snout but youd have to do some homewrok to make sure they unit fits your blower. I believe magnesun sells a snout kit designed to be cut to length to make blowers fit special applications.

dave

[Wanda]

Great information as always, especially the detail

Now It's just a matter of finding it (eBay isn't helping at the moment )

Anyways, today i'll be collecting an intake manifold (to fabricate), probably some pieces of metal also...I think it's better to deal with the manifold first

Then the fabrication of an elbow is next (from throttle body to S/C inlet), (unless i can use a "u-bend" piple with exit flanges that can be fabricated)

Thanks again for the info..

[m44lee]

look forward to seeing the progress mate
make sure you take plenty of pics throughout

[Wanda]

Originally Posted by m44lee

look forward to seeing the progress mate
make sure you take plenty of pics throughout

Thanks Lee, i'll definitely do so..

Tiny update:
- Managed to get a lower-intake manifold & gasket
- Spare Injectors (incase mine break!)
- MAF Sensor (my m43 uses a flapper AFM)(wiring won't be easy since MAF has 4 pins & my AFM has 5 pins..)

Sorry for lack of pictures now, I'll be collecting some more bits next day anyway...

[pdxmotorhead]

The MAF is not a direct swap on the flapper door units at least on M42 vs M44 its not. ,,, unless you found something new and if you did WE WANNA KNOW!!!!

FYI the flapper has little affect on horsepower its been tested pretty thoroughly, single digit percentages until you get north of 200HP...
Dave

[Wanda]

YAY!, the mercedes S/C finally came today!
(Yes, all pictures are being uploaded later today when i get home... I'm at work at the moment)


BTW, @pdxmotorhead - the merc. S/C has a clutch on it. What is the best way to remove it ? as i feel like i might not need it. Having a clutch might complicate my build progress

Thoughts ?

[drowan]

Originally Posted by Wanda

Thanks for the heads up, i'll look in to that part.



The kit comes as new and equates to $1,250 USD as a whole. The oil cooler included, i guess that means the unit is oil-cooled only. Would you think that's still a chinese knock off ?
Lol, it's not easy to tell from just looking at the images as i'm not an expert at this. (I might ask the seller where it's from)

Regarding what the seller said about engine size, here's the response:

Hi, the parts work on your car. You just need a turbo manifold and downpipe, 
which is not included in the kit.

The piping is universal, so yes I was aware i will encouter this obstacle...
The engine bay might need a bit of shaving up (relocation of certain things), just so the piples can move freely.
With the car being an RHD, the steering column is a problem already, as it is under the manifold already, so pipes will need to find alternative routes to connect... and possibly extending them also...



Yeah, when it comes to installing i won't be alone lol, the car will be at a garage with some to help assist with the tuning...

Ofcourse, I'll be doing a build thread since i need to keep track of my own progress too. (with a busy life, it's easy to forget things)

It sounds like the kit I bought (from ebay) some things I used others i didnt and bought new name brand models. The only problem I see in the future (depending your engine bay and engine mount set up) is running a wastegate screamer pipe or finding a way to recirculate to your exhaust. My 318ti has almost no room for a pipe inbetween the manifold and the strut tower. Also make sure your kit comes with all the proper fittings (mine didnt and some are almost impossible to find) good luck with your project and whatever you decide to do.