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Old 12-03-2013, 03:18 AM   #1
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Default Supercharged Frankencar; Dem Throttle Responses and Typical BS

I am getting bored of trolling on club toaster and since I have been on here more decided to move my build thread. Yeah I know, migrating from CR and supercharger. Let the flame fest begin. There may be some cool things here, maybe not. Also the following post may be slightly disjointed. I bought the car ten years ago and was my first car. This covers that span of time and all the iterations it has had.
This is pretty much how the car looked when I bought it. The only mods visible at this time were a hardtop and the headlight cover I made.



I got tired of my car being slow so I supercharged it. In retrospect this was not the best decision. Open diff, stock suspension… yeah fun times



Added a roll bar so I didn’t die as much.



I hated the giant pop ups since I am short and they block my view so I adapted a set of Eagle Talon lights to the car.





Also got some 6ULs to replace those shitty wheels.



A set of Tien Flex Later



I then dabbled with an air water Intercooler setup for a while. That thing was a turd. I recommend never getting one.



I got tired of the powercard sucking so I built a megasquirt for the car.







Designed my own shiftlight because racecar.





Finally got rid of the air water intercooler and went to an air to air setup. Couldn’t have been happier. Well at least for the time being.



Then I took it and got it tuned. Made 190 to the wheels which was respectable.



Because Racecar



Designed my own hood for cooling.





And now for what I do with the car. Besides letting it sit most of the time I try and get out and track or autox it whenever I can afford it. I am a grad student now so I have dozens of dollars and another project car. Recently been getting quicker with it. Managed a 44.55 at Adams Kart Track in Riverside.
















Made a wing for the car. Here it is at its lowest angle. At higher angles it makes a huge difference on small courses.





Some fun at Seca







And hardparked next to my Volvo at seca



Then the supercharger bracket cracked and I removed the blower. I was sad.



No me boosta



So I was in the junkyard looking for a few parts and was drawn to the magnificent curves of this engineering feat. A 1995 Buick Riviera!



Well not really. But they have a 3rd gen m62 supercharger in them and the nose on it looked very similar to the m45 in the Jackson racing kit. Sure enough the noses interchange which means the front bracket for holding the blower to the head fits on.

So here is the blower on the bench once everything has been stripped from it.



Since the blower is fairly long I took a sawzall and cut off the back flange to get a little more room.



I then drilled the two holes near the top and tapped them. Where they are located you can drill all the way through and not hit anything important.



Instead of using a miata throttle body I decided to use one from a volvo. The 16v 740 series has a fairly slim throttle body. The same throttle body should be on a volvo 850 turbo too. The Throttle body lines up perfectly with the holes I drilled out and is exactly the same size as the inlet.





Only the top 2 bolts for the throttle body go into anything. I plan to jb weld a thin plate to the blower between the blower and tb to block some passages I dont need. With rtv the tb should seal fine.

Here it is in the car. Fitment is tight with the firewall.



And lastly the m45 nose on the m62.



Making the bracketry



Building the outlet manifold







First intake design using the DDM intake I had. It could not keep up with the M62 and the filter imploded





Second intake design



I decided I didn’t like the fitment in the back for that intake



So intake design number three



Finally did a coolant reroute for my car just in time to go to Adams Kart track tomorrow. Trying to get as much done as I can before I start on my PhD next week. I did a simple diy setup by flipping the front and rear thermostats. For the hose I used Autozone part XL 1215. Don't know the correct application for this hose but it is $20 and works very well.

Here is the 1.8 thermostat cover on the back of the head. Probably would interfere with the normal coils but I have coil on plug so plenty of room back there.



I needed to cut the hose and join it with a 90 degree turn to go down to the waterneck on the back of the head. I made this pipe with both a mounting tab and a bung for my coolant gauge to do so.



Here is the hose going to the back of the head with the above part mounted to the valve cover.



And the” finished” project (well two years ago).







More ribs for her pleasure. I got a few more ribs cut into the overlay pulley that I had so now I can run a six rib belt. The tensioner pulley fits a 6 rib belt. I need to get another buick nose pulley though since I messed up the one I had. It happens to be slightly smaller too which will mean time for more boost.





Had some problems and needed to remove the blower. So while it was out I ported the outlet which seemed to help a lot.



I finally decided to put an oil cooler in the car. Something it desperately needed. I used a volvo cooler with a cooltek thermostat and mated it to the oil filter relocator I had on the car. There was no space in the mouth of the car so I had place it on the steering rack.







Did something not racecar. Although it was nice that the protege Valve cover relocated the breather line to a place where it was no longer crushed shut by the blower.



And some more current pics



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Old 12-03-2013, 03:28 AM   #2
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New motor hopefully going in this weekend.

NA Block:

Bored out to 1.9+
GTX Rods
OE Replacement Pistons

99 Head:

Supertech Oversized Valves
Mazdaspeed Miata Intake Cam
Gutted Intake Manifold.



Here are the pics of the gutted manifold (left) next to a stock one. I have seen dynos of this helping a lot with top end power.



New engine is in and running like a champ. While pulling out the old motor I found a lot of interesting things which in order were:

Radiator was missing a lot of coolant and reservoir dry.
Intercooler had a hole in it near a sensor I put in
Front main leaking
Only one motor mount bolted in. Other nut peaced out
Missing coolant possibly found, in the exhaust port of #1...
Rear main leaking

Anyways some pics







Raiding the old motor for parts



Engine out





Engine completed. Decided to break in the motor naturally aspirated to get rid of the temptation to full throttle.





So the motor didnt survive. This was a known possible outcome for it since it was originally in a different car for a bit car and had oil pressure issues then. A few hundred miles into the breaking compression was low and it seemed to be burning oil. Leakdown also showed issues as well. Peaked in there with a borescope and saw some vertical scores. Popped the head off and it didn't seem to happy inside. So time for a new plan.



While I had the header out I decided to do something about the nasty internal welds that block a bunch of the ports.



So I welded the header from the outside and proceeded to grind the welds down. Not done yet but it looks a lot better.



Worked on my new manifold a little today. Burnt up the few tips I had and the only "hardware" places near where I live are useless chain stores. The material I am using is a little too thick for my welder which is part of the reason I am killing tips. I need to hold the gun super close or else I can not get a pool started and sometimes it would melt the wire in the tip. And yes I do suck at welding aluminum but hey I just started and it is MIG not TIG.





Ok lets try this again after waiting 4 months. Hopefully this one lasts.

96 block
9:1 CP Pistons
Manley Rods
ACL Bearings

99 Head
Msm intake cam
Supertech 1mm over valves.



Engine in the car with the mess it made in the background.



Did a little more work today. First I worked a bit on making the ports on the intake manifold smooth, got bored and decided to do something else. I then fitted the blower and worked a bit more on the supercharger manifold.



Here is the plan for the hotside piping. I need to get another piece of pipe since all the chunks I have are too short. This was the best I could come up with that still made getting to the radiator cap possible. Only problem is the headlight motor needs to be reclocked for this piping routing to work so time to modify the headlight bucket.



Got it running today. Car made 14 psi at 4000 rpm and partial throttle. The throttle response is epic with the 3 inch throttle body and larger intake. Boost will rise as fast as you can depress the pedal. Motor is still to young for doing that though so I don't know yet what the final numbers will be. Didn't have the blower alignment quite right though and the belt jumped a tooth and demolished itself.











Worked a bit on the mounts for my wing. Still need to weld it all together. I forgot to take pics so this will have to do.



The mounts are similar to the ones I built on this car.



Productive day and I didn't even have to do much work! Started off by taking the car to be tuned. It made 241 hp and 224 ft-lbs at 13 psi of boost. Ambient weather was 80 and this was after several pulls so the system was warm at that point. I also asked for a conservative tune so there is more power in there.



Then after took it over to 949 Racing to have Sonny corner balance and align the car. First alignment in 4 years lol.



I tried the car at adams kart track and the throttle was super sensitive making the car impossible to drive. There was no difference between partial throttle and full throttle. Been working on a dual throttle body setup in hopes of fixing that. I mated a volvo 960 3" throttle body to a maf adapter and placed it above the valve cover. Funny thing is this was built with parts I had laying around lol. Car is much more drivable now and it quieted the blower down. Also eliminated the surge the car had on shifts.



And another pic of dat ****



Coolant temps with the fron mount were too high so decided to switch to a V mount setup. A little bit of progress for the new intercooler.



Here is the underside of the IC. Now that I can weld aluminum I added a bung for the IAT and welded plates on to make areas thick enough to tap threads. I used to just jb weld things on and this should work much better.

Also before someone goes " blah blah rable rable bov on supercharger is stupid" you need one if you run either dual throttled or unthrottled. Compressor surge with a blower is gnarly. I am actually quite happy with this bov placement since the hotside outlet pipe blows directly at it.



There is surprisingly a decent amount of space between the hood and the core. I plan to test it and see how well it cools. If I need it to cool better, I may cut the hood. I also plan to run separate ducting to the ic so it will probably not be needed.



A little more progress. I did some testing with the IC and found it almost as efficent as the front mount. It would heat soak pretty bad at idle though so I added a fan and that seemed to fix the problem.



I also added a scoop for the IC. No data on that whether that helps or not.





I also installed a Jackson Racing header. Last time it will look this pretty or be visible since I am covering it with a TDR blanket.



Converted to sport brakes as well. Only did one drive on them and they feel like crap. Turns out the NBs uses a larger master. Makes sense since the larger calipers need to have more fluid displaced. They work right now but have to depress the pedal a ton. Need to remedy this.



Lastly I mounted an old phone inside the car to read the MS. These are not the gauges I went with since they are too hard to read. Never got another pic of the changes. The other cool thing is I can change maps with the phone. I decided now that I can do that I am going to switch to running e85. Time for more power.



Some work on the front aero to match the rear. The design is similar to the one I helped Sonny build on his msm except this one is completly suspended by cables. I found that if I ran a cable from far back all the way to the front of the bumper, (3rd pic) it pretty much eliminates any rotation of the splitter. It is pretty stable, supports my weight and quick to remove. Also I left a gap between the bottom of the airdam and the splitter which is filled by the garden edging. Still need to clean up the cut but the benifit is this allows it to flex upward a decent amount.









Finally painted and on the car. Still need to do ducting.



And some fun that helped in aero design. Drew a model in solidworks and did some testing.

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Old 12-03-2013, 10:14 AM   #3
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One of the more interesting SC builds, good stuff, and thanks for all the pics.
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Old 12-03-2013, 11:09 AM   #4
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Nice build. good numbers.

any idea why the torque drops off so hard in the upper rpms?
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Old 12-03-2013, 11:33 AM   #5
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I am pretty sure the torque falls off because the boost pressure used to fall from 14 to 12 at redline. Also that dyno was with the stock header. I tried to hunt down the boost problem but couldnt ever find it until now. I got tired of the actuator failing so I decided to permanently close it and use a Mini Cooper one instead. First pull with the Cooper one and the BOV was leaking and it made only 10 psi. I re tightened it and now it holds 14 steady. The boost gauge is fluttering so I think the bov still may be leaking. I plan to put the second spring back in and see what happens. Originally with the old bypass I had both springs in and bov fully tightened so I am pretty sure the prior boost issue was from the bypass.

Another possible cause is the head had been shaved enough to retard both cam gears 2 degrees. Also funny story with that. I was retarded and put the crank gear on wrong. So rather than fix it, I just used the cam gears to sync the MS timing. Since they were retarded, the ignition timing was retarded a bunch and I didnt figure that out until after the dyno. So car made probably more than 240 on pump after fixing the timing.

Also that dyno was on CA 91. Now on e85. Hopefully will be back to the dyno soon.

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Old 12-03-2013, 11:35 AM   #6
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The car looks great man. You've done some really impressive fabrication, I wish I had those skills. Keep us updated on the progress.
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Old 12-03-2013, 06:03 PM   #7
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That is pretty damn cool.
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Old 12-03-2013, 06:23 PM   #8
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Very awesome and unique build you have here. You definitely belong here
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Old 12-03-2013, 06:43 PM   #9
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Quote:
Originally Posted by Fireindc View Post
Very awesome and unique build you have here. You definitely belong here
Well except for the lack of turbo lol. Although both DDs I had were turbo. The last one was a volvo 940 ended up being way too much of a project. Built motor, T3/T4 turbo, 20 psi and all sorts of lols.







And the current dd is an msm. Plan to leave it alone and not repeat the volvo.

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Old 12-03-2013, 07:13 PM   #10
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As someone who just ruined their DD due to similar shenanigans, i would agree with your plan.


Except that why in the hell did you pick an MSM? Those things are painful to drive in stock form. They NEED an aftermarket ECU at the bare minimum. :P
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Old 12-03-2013, 07:40 PM   #11
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It has the full flyin miata intake on it so it is not that bad. Some day plan to put a DP on it to complete the package. Main reason for an msm is it is more Cali friendly. Also ECUs are bad. Once I do that I could just throw down some pennies and go to town with the welder building some setup with enough boost to pop the motor. I have like two spare blowers and a turbo or two in the collection of random bits. Stupid junk yard half off days.
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Old 12-03-2013, 07:43 PM   #12
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Well except for the lack of turbo lol.
The turbo thing is far from a priority on this forum, despite its name. The site could just as well be "functionalmiata.net", as that's all most of us really care about. As for your stoopidcharger setup, it's awesome and I would gladly have it on my car.

LOVE that volvo wagon, sick sleeper. MSM is a hell of a nice daily too, imo.
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Old 12-03-2013, 08:14 PM   #13
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followed your volvo build on CR, but didn't know you had a miata build. Glad I read this thread, its definitely very cool. Great work!
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Old 12-03-2013, 08:15 PM   #14
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Props given. Awesome job. May be stupidcharger, but you are creative and resourceful and the results are strong!

Although... I just can't help thinking what you could have done with a turbo and that amount of time and effort...
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Old 12-03-2013, 09:31 PM   #15
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Props given. Awesome job. May be stupidcharger, but you are creative and resourceful and the results are strong!

Although... I just can't help thinking what you could have done with a turbo and that amount of time and effort...
Probably could have built some 350+ hp monster which is not what I am going for. The longblock itself would have no problem with that. I have a feeling this will give more than enough power for what I want to do with the car.
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Old 12-03-2013, 09:36 PM   #16
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Props given. Awesome job. May be stupidcharger, but you are creative and resourceful and the results are strong!

Although... I just can't help thinking what you could have done with a turbo and that amount of time and effort...
thats your 949th post! haha
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Old 12-03-2013, 09:46 PM   #17
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Very cool build. You belong here.
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Old 12-03-2013, 09:58 PM   #18
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thats your 949th post! haha


Wahoo!
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Old 12-04-2013, 12:57 AM   #19
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followed your volvo build on CR, but didn't know you had a miata build. Glad I read this thread, its definitely very cool. Great work!
link to said volvo build?
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Old 12-04-2013, 02:56 AM   #20
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Here is the Volvo build. So much win but so much fail. Thing would pull on evos and stis but broke the most random things all the time so I sold it.

Volvo 940 Daily Driver - ClubRoadster.net
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