Supercharged Suzuki Vitara 1600 16v Project

jeremyisme · Post by **jeremyisme** » Sun Dec 17, 2006 4:22 pm

Ok, it begins now.

Hopefully I will be able to keep this thread up to date with the build.

Right, I got the supercharger on Thursday, it was very oily, and dirty. And I found a 2cm long piece of metal shard inside, from someone cross threading one of the intake bolts!!!. Even worse, I had turned the pulley a few times before I saw it, which ground it up a bit. I have flushed some petrol through it to wash away as much oil and rubbish as I can, and it looks much better now.

I found a thread on another forum, that said the toyota SC12 supercharger rotates clockwise, which is good, as that means it wil rotate the same way once I mount it in the Vitara.

Here is the supercharger

The first thing I have done is relocate the power steering reservoir. As it is definately going to be in the way.

It wasn't too difficult, I just got some new hoses from Enzed (prolly paid too much I think) and made a new mount for it, close to the firewall. I ran the hoses low down to keep the out of the way of anything.

My only problem was that one of the hoses was too big, but I just clamped it down tight on one end, and really jammed the joiner into the existing hose really well, hehe, one day I wil replace it with the correct size hose.

Before

After

And here is a pic of the new extractors I put on. They give me a bit more room in the engine bay to work with.

The next thing I have to do is try to make some mounting brackets for the supercharger. I am going to try to mount it above the AC, as I want to keep my AC! Which means I will have to get new hoses made for the AC compressor too, as the metal sections stick up too high and will get in way of the supercharger.

De-Ranged · Post by **De-Ranged** » Mon Dec 18, 2006 7:05 am

:thumleft: Nice start, just out of interest did you dyno it before you started, hmmm flag that I was just thinking theres probably noone in town with one

....

just me, I like to know how much I get off each bit bang for buck sort of thing

Oh and nice to see the anti-seize on the exhaust bolts :roll:

I wish the last bastard who worked on my rover had done that.... I've got a bastard job now couse two out of three broke!!

Cheers Reece

jeremyisme · Post by **jeremyisme** » Mon Dec 18, 2006 9:15 am

There isn't any anti sieze on the bolts yet, but that has reminded me to do it before they do sieze up!!

I haven't got access to a dyno down here in Qtown, but I am hoping that I can get Street Dyno to work properly, so I can at least get an idea of the increase. Or else I will get one of the G-Tech accelerometers from Trademe.

I have been looking in the engine bay with regards to how much room I will have for the supercharger, and it is not looking good for the AC. I think I may have to loose it, otherwise the supercharger might be sticking up through the bonnet.

I am also going to have to relocate the air filter box. As that is getting in the way too. I don't want to put a pod under the bonnet, incase I start sucking water in.
So what would be the options be for that? I would like to just keep the stock inlet in the guard but have a smaller air filter box or something like that.
Any ideas?

De-Ranged · Post by **De-Ranged** » Mon Dec 18, 2006 9:59 am

As for space.... that I can't help with I've never worked on one before so I've no idea

As for gard vs engine bay .... I'd say relocate it to the rear of the engine bay that is normally the last bit to go under... have a look at Moriarty's posts he did this to his sanyong with good results

If you want to go extreme

another option (something I'm considering for the Lemon) is right infront of the passanger is a loverly box all premade for a filter.... cut a whole in the firewall plumb the filter into the back of the glovebox with a hard mount and flexy from that to the intake of the supercharger all you would need to do is seal the box and run a whole to the air intake vents for the cab air vents or you could then run the snorkle up inside the cab :wink:

nicely protected!!

Cheers Reece

mroffroader · Post by **mroffroader** » Mon Dec 18, 2006 7:33 pm

As for airintake do what I ahve done, http://www.offroadexpress.co.nz/modules ... 92&start=0 ........except take out the air filter and do it from where the airfilter box was and don't go so far up behind the dash and wack a cheap washable pod filter on it form super cheap or similar $40-50 from memory and enjoy that (totally legal) intake sound :lol:

turoa · Post by **turoa** » Mon Dec 18, 2006 7:39 pm

mroffroader wrote:As for airintake do what I ahve done, http://www.offroadexpress.co.nz/modules ... 92&start=0 ........except take out the air filter and do it from where the airfilter box was and don't go so far up behind the dash and wack a cheap washable pod filter on it form super cheap or similar $40-50 from memory and enjoy that (totally legal) intake sound

If hes keeping his aircon, I dont think hes the kinda person who wants a WRX in their glovebox

mroffroader · Post by **mroffroader** » Mon Dec 18, 2006 7:54 pm

turoa wrote:
mroffroader wrote:As for airintake do what I ahve done, http://www.offroadexpress.co.nz/modules ... 92&start=0 ........except take out the air filter and do it from where the airfilter box was and don't go so far up behind the dash and wack a cheap washable pod filter on it form super cheap or similar $40-50 from memory and enjoy that (totally legal) intake sound

If hes keeping his aircon, I dont think hes the kinda person who wants a WRX in their glovebox

not quite sure what to say to that....

doing my aircon to aircompressor hopefully friday night

jeremyisme · Post by **jeremyisme** » Mon Dec 18, 2006 7:59 pm

Haha, the aircon thing is just cos Qtown summers can get really hot, so i would quite like to keep it if I can. And it is good for demisting windows etc.

so mroffroader, your air intake thing was completely legal and good? It might be a cool sound with the supercharger.

Madaz · Post by **Madaz** » Mon Dec 18, 2006 9:21 pm

dude; I had my intake ducted inside the truck and trust me ,its not a sound you would want to live with day in and day out!!!

Madaz · Post by **Madaz** » Mon Dec 18, 2006 9:45 pm

mroffroader · Post by **mroffroader** » Tue Dec 19, 2006 6:35 am

Madaz wrote:dude; I had my intake ducted inside the truck and trust me ,its not a sound you would want to live with day in and day out!!!

AYE!!!!!???? if you dont put your foot down you never even hear it....its only if you put your foot to the floor passing someone down the motorway or taking off quickly that you even hear it........yea becuase another welly guy on here bubba copied :oops:

me and he went down to the certifiers and said if i do this do i have to cert it and they said no :twisted:

so its legal........ :wink:

mroffroader · Post by **mroffroader** » Tue Dec 19, 2006 6:37 am

Madaz wrote:dude; I had my intake ducted inside the truck and trust me ,its not a sound you would want to live with day in and day out!!!

maybe theres a difference in sound with that 1300 carbie and the 1600 fuel inj.? becuase it actually doesn't sound too bad like its not a ugly sound

De-Ranged · Post by **De-Ranged** » Tue Dec 19, 2006 7:01 am

hmmmm with a supercharger, I'm with Madaz on this especially if this is a daily driver

Seal it up in there so its not pulling air from the cab and duct the inlet to the cab air vents or runn a snorkle up the inside of the cab and out the roof

Oh and another bit of advice don't stimp on your air filter.... you get what you pay for... buy a decent brand washable high flow, don't get a budget one, all you will be doing is reducing the life of the supercharger and motor

Cheers Reece

jeremyisme · Post by **jeremyisme** » Tue Dec 19, 2006 9:48 am

Yeah, you might be right about the noise since it will be a daily driver.

I am thinking it might be ok to just run a pod under the bonnet for while now, until I get it all running well, just as long as I dont do any big water crossings etc. I guess as close to the firewall and as high as I can get it would work?

Madaz · Post by **Madaz** » Tue Dec 19, 2006 9:19 pm

Dude, theres a F...ken HUGE difference in intake noise with a supercharger running in the intake line,These sc12 blowers suck enough air at idle to suck a hand on to a 2.5inch intake and hold it there!

Madaz · Post by **Madaz** » Tue Dec 19, 2006 9:19 pm

Dude, theres a F...ken HUGE difference in intake noise with a supercharger running in the intake line,These sc12 blowers suck enough air at idle to suck a hand on to a 2.5inch intake and hold it there!

mroffroader · Post by **mroffroader** » Wed Dec 20, 2006 6:00 am

Madaz wrote:Dude, theres a F...ken HUGE difference in intake noise with a supercharger running in the intake line,These sc12 blowers suck enough air at idle to suck a hand on to a 2.5inch intake and hold it there!

oh right i see :shock:

ok yea maybe just put under the bonnet and then save up for a proper snorkel :roll:

i didnt that it was THAT much of a difference :shock:

Bubba · Post by **Bubba** » Wed Dec 20, 2006 9:13 am

mroffroader wrote:
Madaz wrote:dude; I had my intake ducted inside the truck and trust me ,its not a sound you would want to live with day in and day out!!!

........yea becuase another welly guy on here bubba copied me and he went down to the certifiers and said if i do this do i have to cert it and they said no so its legal........

Copied! Copied! Checky little shit! yes it does sound very cool, it brings out the WRX inside every Zuk but's it not a overpowering db, unless you want it to be. I noticed a difference in power but an increase in fuel consumption mainly because my foot got heavier, love that sound.

Anyway, a very interesting thread dispite James rambling :wink:

Looking at the photo on the Supercharger, even with moving the Power steering are you still going to have room for it. Worse case situation you cut a hole in the bonnet and have a bonnet scoop thing, might look cool.

As for a Pod under the bonnet, I wouldn't risk it. It wouldn't take much more to make a very cool looking sknokel.

Oh yeah, MrO, your Mumma's hairdresser called, they want their car back! :lol:

jeremyisme · Post by **jeremyisme** » Wed Dec 20, 2006 9:43 am

Yeah, I have measured it up, and if I get some new fittings for the AC it will fit, just.

My next problem is how to power it, I was going to run just a longer belt that cover the PS, AC and supercharger, but that won't work very well for the AC, as the belt will only touch a small part of it's wheel, so prolly won't even spin.

I thought about getting a new crankshaft pulley made, but there isn't any more room between the crankshaft pulley and the radiator fan, so that won't work.

My next idea is to attach another pulley onto the PS pulley, and run the belt from that up to the supercharger. I might have to tension up that PS, AC belt more to stop it slipping, but I am figuring it might work alright. The only problem I see with that is getting tension onto the PS pulley (additional one) to the supercharger pulley, I reckon maybe a tensioner in there somewhere?

What do you think?

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Bubba · Post by **Bubba** » Wed Dec 20, 2006 9:52 am

Ditch the AC, replace with the charger, wouldn't that fix it. I know you want to keep the AC but .......................... Then again I'm talking from a hole in my ass, so ..................... :roll:

jeremyisme · Post by **jeremyisme** » Wed Dec 20, 2006 10:17 am

Yeah, I know, but that is the easy way!!!, haha,

I would really like to keep it, unless there is no way to engineer it in.

But at the moment I can still see potential to keep both, even if it means it is a little more difficult.

I would like to have this as a comfortable daily driver, but with a supercharger!!, hehe, who knows if that is possible though.

mroffroader · Post by **mroffroader** » Wed Dec 20, 2006 11:24 am

hey rod i think my mums hair dresser thought my car was your car... must have got them confused so she wants her car back.......hahahahahaha :p ................anyway back on topic stop rambling rod hahaha.......ditch the air con because you still have a fan that blows cold air and you can wind your windows down we dont live in the outback its not really needed mine stopped working as of about 10pm this morning as i cut it all out :twisted:

im turning it into a air compressor......u going to copy me with that aswel rod hahahahahahaahaahaahaahahaahaahaha :lol:

jeremyisme · Post by **jeremyisme** » Wed Dec 20, 2006 1:15 pm

Right, I have just spent my lunch time checking out a couple of wreckers. I went to John MacKenzie wreckers here in Invercargill, and one of the guys gave me a pulley about the right size and a large idler, which was nice of him. So I will try fabricate up something that will mount off the PS pulley and see what happens.

He pointed out that it might be too much pressure on the PS bearings, but I guess I will just see what happens and cross my fingers.
PS bearings can't be too expensive right??

mroffroader · Post by **mroffroader** » Wed Dec 20, 2006 2:50 pm

jeremyisme wrote:Right, I have just spent my lunch time checking out a couple of wreckers. I went to John MacKenzie wreckers here in Invercargill, and one of the guys gave me a pulley about the right size and a large idler, which was nice of him. So I will try fabricate up something that will mount off the PS pulley and see what happens.

He pointed out that it might be too much pressure on the PS bearings, but I guess I will just see what happens and cross my fingers.
PS bearings can't be too expensive right??

i had a loook at mine and that seems like the best place to put it i suppose if its not on a slight angle and you don't tension it too much it should be ok on there

spanky · Post by **spanky** » Wed Dec 20, 2006 7:58 pm

bearings might be cheap, but you know were you will be when it seizes, these blowers need a bit of tension on the belt so it doesnt slip and eat the belt. last one we did was blower on rwd ae 86 corolla and was surprised how tight the belt needs to be to not slip and that was using a new gates race belt. i would make double pulley for crank run seperate belt and you need to get a tensioner in there as well.
vaughan

jeremyisme · Post by **jeremyisme** » Wed Dec 20, 2006 8:40 pm

Yeah, I thought about using the crank pulley, but it will have to be a triple, cos the vitara has a belt for the pump, fan, alt and another for ps and ac.

I am going to have a go at doubling up the ps pulley when I get back to Qtown this weekend. Hopefully it will be balanced alright.

I went and got 2m of stainless steel 2.5" pipe for my intakes and piping etc today, I think 3" aluminium is going to be too thick (3mm) and maybe too big, and they didnt have any 2.5", so 2.5" stainless it is, hehe, prolly a little overkill, but oh well.

I did get 1m of 3" aluminium though, maybe for a short section or something.

The guy took pity on me when I told him my project, so he gave me a good deal, haha.

jeremyisme · Post by **jeremyisme** » Wed Jan 17, 2007 12:33 pm

Does anyone know how I can control the boost on this? I am thinking of using a BOV, but I am worried that they will not go low enough, i.e. 4-5psi that I want to use at the start.

Any ideas?

spanky · Post by **spanky** » Wed Jan 17, 2007 8:47 pm

boost on a supercharger is controlled by how fast it spins, have a look how big your pulley on the blower is and also your crank pulley compared to standard toyota ones , i can measure 4agze pulleys tomorrow and post there size cause they boost 1 psi per 1000 rpm which would be sweet on your motor as on the limiter you would only have 6.5 psi. what intercooler are you using?.
vaughan

Madaz · Post by **Madaz** » Wed Jan 17, 2007 8:54 pm

Yeah Spankys right - you shouldnt make too much boost.
The best way to find out is to take it for a CAREFUL test drive-( stop if it hits 20lbs) :lol:

But seriously working out how much it will pull is all good, but NOTHING beats real world testing :!:

Good Luck

Tim

jeremyisme · Post by **jeremyisme** » Wed Jan 24, 2007 9:20 pm

I am going to try use an intercooler from a Celica GT4, however, I am going to have to modify the inlets and outlets to make it work.

Anyway, update so far, I have made half of the mount for the supercharger, and it seems to be sitting in the engine bay alright. I will finish off the rest of the mount this weekend and post some pics.

In the mean time, I have put on a pod filter, so I can take out the air box while I am doing all this, as it was getting annoying having to take it apart every day after work when I was working on it.

I have also almost got the adjustable fuel pressure regulator in, just waiting on one more fitting tmrw. Then I should be able to up the fuel pressure once I connect up the charger so I don't run too lean.

Oh, and I have put in a air fuel ratio meter (just a DIY one I made a few years back)

The plumbing of the whole system is going to be the most difficult part I think.