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Author: Subject: Duratec install progress - sump construction underway
flak monkey

posted on 22/12/09 at 04:16 PM Reply With Quote
Ahh I just read brooke cars have squeezed 400bhp out of a supercharged duratec!





Sera

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Micael

posted on 22/12/09 at 06:32 PM Reply With Quote
add this head and you can go even further

http://www.motordesign.se/start.asp?page=3en





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goaty

posted on 23/12/09 at 09:45 AM Reply With Quote
wonder what that costs....I know a race head is looking the best part of £1300
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flak monkey

posted on 27/12/09 at 07:56 PM Reply With Quote
Got the supercharger mount 90% finished today. Need to tidy up some of the welds and cap the ends of the box section.

The box is 20x20x1.5, the laser cut plate is 6mm steel. The box has crush tubes welded in where the bolts go through.

The alignment is pretty good I think. Within about .25mm. Having had a measure up for a shim, it only needs a 0.7mm shim behind the front bolt at the bottom to make it spot on.

Having done some calcs the supercharger is going to pull around 15bhp at 7250rpm and 14psi boost. Hopefully the brackets will take it.

Charger mounting 4
Charger mounting 4


Charger mounting 5
Charger mounting 5


Charger mounting 6
Charger mounting 6


Charger mounting 8
Charger mounting 8


Charger mounting 9
Charger mounting 9


[Edited on 28/12/09 by flak monkey]





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goaty

posted on 28/12/09 at 08:13 PM Reply With Quote
looks very good dave, looks nice and tight to the block too which is vital
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flak monkey

posted on 28/12/09 at 08:18 PM Reply With Quote
Thanks, yep theres not much space. The laser cut plate is touching the front cover, I need to trim a little off it. Theres just enough space to get the oil feed banjo on next to the block

Had a measure up today and defo need to move the steering column. Will wait to get the engine in and see where its going to fit!





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goaty

posted on 28/12/09 at 08:20 PM Reply With Quote
lol, i was thinking the same. may have to move a few bits and bobs
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sebastiaan

posted on 28/12/09 at 09:02 PM Reply With Quote
15 HP at 7000RPM (i'm assuming crank and compressor pulley are approximately the same diameter) equates to 15Nm of torque or, when using a pulley diameter of 3 inch, roughly 200N of force on the outer edge of the pulley. Looking at the brackets you've made, the compressor might try to rotate around its height axis. Could you add a gusset between the box section of the bottom mount and the lasercut compressor mount plate to prevent this? It looks like it would need to be below the box section and that you'd need to switch to allen bolts.

Does this make sense?

[Edited on 28/12/09 by sebastiaan]

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flak monkey

posted on 29/12/09 at 08:44 AM Reply With Quote
Thanks for that. I did wonder about fitting a gusset at the bottom. Would need to weld another piece of plate on along the bottom of the laser cut plate though.

I understand where the torque fig comes from, but not sure about the force one?

If the pulley needs 15Nm of torque to turn it at 7000rpm then the force is the radius of the pulley divided by the torque isnt it? So for a 3" pulley that would equate to 400N.

The pulley on the supercharger is 95mm OD so the force would be 315N or ~32kg. I may end up with a smaller pulley though, depending on how much boost is lost in the rest of the system and how mental I feel once I have driven it for the first time!

ETA: Just found this

http://www.tribology-abc.com/calculators/e3_5a.htm

Plugging the relevant numbers in gives a shaft load of 302N so the calcs above arent far out.

[Edited on 29/12/09 by flak monkey]





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flak monkey

posted on 30/12/09 at 04:31 PM Reply With Quote
Finished the supercharger mount yesterday morning, and just made myself a shim to align the pulleys perfectly.

Incidently I found that Gates specify a maximum shaft parallelism error of 0.25 degrees for poly vee drives.

Finished charger mount 1
Finished charger mount 1


Finished charger mount 2
Finished charger mount 2


Finished charger mount 3
Finished charger mount 3


I have also been having a looking at where to put idlers for the best belt wrap on the crank pulley and the supercharger pulley.

I think one of the standard Duratec idlers will work between the crank and the alternator. Need to just swap the bolt out for a 10mm one.

Idlers 2
Idlers 2


I then need to make 2 more, a 45mm and 50mm one for either side of the supercharger pulley





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Snap-off

posted on 30/12/09 at 08:38 PM Reply With Quote
Fantastic work Flak!
That is going to be mental, wish I had the time to tinker again, would love to do another project.
Keep up the good work mate!

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flak monkey

posted on 31/12/09 at 02:07 PM Reply With Quote
Took delivery of a set of Nissan Sunny GTiR throttle bodies with their plenum today.

Plenum 1
Plenum 1


Plenum 2
Plenum 2


Its nicely shaped and has a handy port for the dump valve to be fitted to as well. Its also exceptionally lightweight - which suprised me somewhat.

The idea is to use the plenum, with a modified backplate connect to my GSXR throttle bodies.

I will probably cut the back out of the existing backplate (below) and then have a 5mm thick aluminium plate welded in with stub tubes to suit the GSXR throttle bodies. Then I just need to figure out how to bolt it all together so it doesnt blow itself apart.

Plenum 3
Plenum 3


The port spacing of the throttle bodies does match the Duratec, but sadly I cannot see a way to mount them up to the head particularly easily. Not and keep the flow into the head nice and smooth anyway.





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flak monkey

posted on 2/1/10 at 04:55 PM Reply With Quote
And this is what I intend to make to mate the plenum to the throttle bodies.

The plate is 6mm laser cut aluminium. The adaptors to fit on the throttle bodies fit into this, held on with 4 off M4 dome head screws, loctited in.

GTiR plenum adaptor cad
GTiR plenum adaptor cad


The adaptors themselves will be turned fom aluminium and glued to the throttle bodies with Loctite 648 retaining adhesive.




Hopefully it should make for a neat and compact solution to feeding the throttle bodies with the inlet charge from the intercooler





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flak monkey

posted on 4/1/10 at 09:06 PM Reply With Quote
Spent the last weekend before returning to work (yawn! ) making the idler pulleys for the supercharger belt and modifying the throttle bodies to fit the adaptors above.

Basically I mounted each one up in the lathe and took a few light cuts to clean up the outer ends

Modded throttle bodies
Modded throttle bodies


This will allow the adaptor plates to be glued on accurately. Just waiting for the material to arrive, then I can get those made.

Sent off the drawing for the plenum backplate today, just waiting for one to be laser cut now!

I also made 2 45mm dia idler pulleys to fit either side of the supercharger pulley to increase the wrap and to keep the belt out of the way of other important things!

This highlighted the fact that I need to shave another 1mm off the front cover. The measurements suggest that this will leave it 2mm thick. If I dont go too mad with the angry grinder!

Idler pulley
Idler pulley


One goes here:
Idler pulley 2
Idler pulley 2


And the other goes in the other bolt hole just below the belt in the pic. Gives loads of wrap on the pulley and hopefully will stop it slipping.

Another poly vee drive snippet of info. Gates' give a rough average of a max of 10hp per rib on poly vee pulleys. So quite a lot really!





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Xtreme Kermit

posted on 4/1/10 at 10:40 PM Reply With Quote
Simply awesome work.

Keep it up!

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FASTdan

posted on 7/1/10 at 09:14 PM Reply With Quote
Looking very good indeed. Good idea using the GTIR stuff - had no idea they ran individual TB's as standard.

I'm coming round to this supercharger lark.....





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flak monkey

posted on 16/1/10 at 06:05 PM Reply With Quote
Finished the assembly of the engine today

Setting up the cam timing:

Cams fitted 2
Cams fitted 2


Left the cam sprockets loose to allow the crank to be rotated to TDC before tightening the bolts up to lock off the cams.

Cams fitted 3
Cams fitted 3


Finding TDC
Finding TDC


I then fitted the front cover, sealed with Loctite 5900. Managed to shear one of the bolts off though, so will be drilling that out tomorrow!

Then fitted the new cam cover gaskets and fitted the cover. The water pump pulley. Just need to get some longer M6 bolts for the idler pulleys so I can get them fitted and get measured up for the belt, which will no doubt be fun.

Finshed engine 1
Finshed engine 1


Finished engine 2
Finished engine 2






Sera

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goaty

posted on 16/1/10 at 06:22 PM Reply With Quote
looking bloody awesome, really is coming together. I am waiting to see how it looks with the belt all fitted up, really am going to have problems getting mine in so will help to see ways about bits and bobs.

Keep on trooping

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Benzine

posted on 16/1/10 at 06:34 PM Reply With Quote
Saucier than a direct hit on a Heinz factory!






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flak monkey

posted on 19/1/10 at 07:40 PM Reply With Quote
Finished fitting the idler pulleys tonight, also got a rough idea of the length of belt needed. Looks to be around 2 to 2.1m

Pulleys finished 1
Pulleys finished 1


Pulleys finished 2
Pulleys finished 2


Pulleys finished
Pulleys finished


Looking forward to dropping the engine into the engine bay this weekend to see how it all fits.

Had a quick look at the steering column relocation as well. I might just get away with only one extra joint.

David





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goaty

posted on 20/1/10 at 07:26 AM Reply With Quote
hay dave,
where and what are them idlers from?? coudl do with a set my self....
Also, how have you fixed them all on??
cheers

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flak monkey

posted on 20/1/10 at 08:03 AM Reply With Quote
I made them I couldnt find any the right size.

I put highspeed bearings in anyway.

They are bolted into two of the front cover holes.

David





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flak monkey

posted on 20/1/10 at 06:11 PM Reply With Quote
Another shiney present arrived today. A set of Caterham branded Cosworth roller barrels!

They bolt direct to the cylinderhead, which means I might just be able to keep the plenum inside the confines of the bonnet for the sleeper look. They are only 95mm deep without the trumpets fitted.

The intension is to make a backplate for the plenum to bolt direct to the throttlebodies now, rather than all the bits and pieces I was going to do with the GSXR ones!

I just need to find some much shorter trumpets to fit so I can fit some inside the plenum.

Here follows much automotive pornography!

Oh noes, a box of newspaper!
Roller barrels 1
Roller barrels 1


Maybe not!
Roller barrels 2
Roller barrels 2


Roller barrels 4
Roller barrels 4


Roller barrels 5
Roller barrels 5


I wonder if the Cateringvan lawyers will mind?

Roller barrels 6
Roller barrels 6


And the final thing is I need to find a TPS to fit on here:
Roller barrels 3
Roller barrels 3


I know what I will be doing tomorrow evening





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goaty

posted on 20/1/10 at 07:42 PM Reply With Quote
looks like ford zetec E tps woudl fit that, i do happen to have one lying about too
ps, may get in touch about some idler's too if cool, still got issue with dry sump though, would have to make all the bits to move it across....not good. lol.

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flak monkey

posted on 21/1/10 at 07:27 PM Reply With Quote
Just fitted the new roller barrels. Snug fit next to the tensioner, and looks like I will need an additional spacer to allow the plenum to clear the tensioner. I guess the other alternative is to change the tensioner.

Roller barrels fitted 1
Roller barrels fitted 1


Roller barrels fitted 2
Roller barrels fitted 2


Roller barrels fitted 4
Roller barrels fitted 4


Roller barrels fitted 3
Roller barrels fitted 3








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