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G-Raider 3.0L Supercharger Project #725591
05/25/06 05:12 PM
05/25/06 05:12 PM
FrankR  Offline OP
Web Wheeler
Joined: Feb 2004
Posts: 10,238
Columbia, SC ****
Enough mental mastication, already! Finally, the fun has begun. <img src="/forums/images/graemlins/kewl.gif" alt="" /> I can only hope it runs well when I've finished. If noodling/doodling time counts, it should be fine after a whole lot of work. In the end, you have to build it, see what happens and adjust accordingly - the essence of backyard/shadetree hot rod effort. I'll post pictures and comments as I go, but since time is scarce, there may be considerable gaps in progress reports.

Bob (87_Montero) was kind enough to bring an engine to me to use for prototype work and it's now on the perch. When this is over, I'll freshen his engine in exchange for his effort.... thanks, Bob! <img src="/forums/images/graemlins/kewl.gif" alt="" /> Sparkem sent a lower intake and fuel rail.... thanks Sparky! <img src="/forums/images/graemlins/kewl.gif" alt="" />

The design goal is simple - add some torque and resulting HP to the 3.0L to give it a little more ability to pull hills in O/D with tires larger than 31s - without resorting to an engine swap (4.3L) or gear change.

How much power? The target isn't set in stone, but if this engine can be increased from 168lb-ft/143HP to ~225lb-ft/190-200HP, the difference should more than do the job.

Additional considerations:
1) Simplicity
2) Easy to tune and repair
3) As near to OE parts as possible without computer changes/add-ons, etc. - work with existing ECU
4) Use of OE fuel pump (don't yet know about that)
5) Reliability
6) Sized to not require major engine modifications for durability (I guess that depends on what you call "major" <img src="/forums/images/graemlins/wink.gif" alt="" />)
7) Relatively inexpensive - this one won't be realized on this project, but should be reasonable compared to the cost of similar aftermarket packages for other vehicles, since a new 4th Gen unit with internal bypass will be used.
8) Retain stock cooling fan
9) Retain good "drivability" manners
10)Can be duplicated by anyone with good mechanical skills and access to machine tools

Here we go -

The first challenge is the fuel rail interfering with overall package height considerations. I got a spare from Sparkem, but found that there's a difference between the '89 and later 3.0L rails. Note the difference in crossover tubes - the '89 rail is on the left, the later model on the right:
[Linked Image]
So, I'm using my '89 fuel rail.

The rear of the fuel rail also presents problems for installed height since the fuel pressure regulator is mounted on top of the passenger side rail and the fuel inlet is also raised:
[Linked Image]
Both have to be dealt with, so they were removed, the regulator hole welded/ground/puttied (it'll be sanded and painted later). The inlet and outlet rail ends were tapped for a 1/8" NPT fitting which may have to be bored out to .260" in order to not be any more restrictive to fuel flow than the I.D of the front crossover tube:
[Linked Image]
Here's the modified fuel rail sitting on the lower intake:
[Linked Image]

I thought about setting up the drafting table in the garage to draw a shop blueprint, but realized it would be easier and faster to make a wooden prototype which is now under construction. It will be used as a reference piece to construct the finished part in the machine shop. Here's the first piece - a 1.375" flange spacer that extends the intake ports up to a level that will clear the modified fuel rails and will support the S/C outlet plenum:
[Linked Image]
Here it is in place on the lower intake:
[Linked Image]
Here's a side view that shows 1/8" clearance above the fuel rails:
[Linked Image]

Now I'm off to Lowe's to get a piece of plywood to make the plenum and S/C plate.

Frank

Last edited by FrankR; 05/28/06 02:05 PM.
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Re: G-Raider 3.0L Supercharger Project [Re: FrankR] #725592
05/25/06 05:23 PM
05/25/06 05:23 PM
JAVYPRO  Offline
Body Damage is Cool
Joined: Feb 2001
Posts: 1,973
Buford, GA USA
Great, good luck on this new venture. Your project might be a good excuse to go visit SC. <img src="/forums/images/graemlins/kewl.gif" alt="" />


88 red Montero with the Dakar Special Edition decals, 438,000 miles (As of 7/23/2012) some occational blue puffing but still strong and counting!!! I am going ppsshhh (turbo), Stay tuned =) ...
Re: G-Raider 3.0L Supercharger Project [Re: JAVYPRO] #725593
05/25/06 05:33 PM
05/25/06 05:33 PM
fasteddy  Offline
Web Wheeler
Joined: Jan 2001
Posts: 13,649
Helen , GA *****
Hey, Frank, Lock up your stuff. I'm coming to see you soon...


Not responsible for advice not taken...
Re: G-Raider 3.0L Supercharger Project [Re: FrankR] #725594
05/25/06 07:21 PM
05/25/06 07:21 PM
LRJ4x4  Offline
Web Wheeler
Joined: Dec 2001
Posts: 11,725
Monterey, CA *****
Frank you just need a CNC machine, I'll check e-bay for you <img src="/forums/images/graemlins/smile.gif" alt="" />


98 Montero with cold weather package
96 Toyota Land Cruiser, fully locked Mall Machine :-)
Re: G-Raider 3.0L Supercharger Project [Re: FrankR] #725595
05/25/06 11:00 PM
05/25/06 11:00 PM
87Montero  Offline
Trail Leader
Joined: Nov 2003
Posts: 5,690
Greenville, SC ***
Frank make 2 of everything you're doing.. I'm making more money than I know what to do with right now! <img src="/forums/images/graemlins/ignore.gif" alt="" />

(I'm almost serious <img src="/forums/images/graemlins/kewl.gif" alt="" />)


1999 Mitsu Montero - Crappy Weather
1992 Isuzu Pickup - Zombie Apocalypse
2008 Saturn Sky Redline - Nice Weather
Re: G-Raider 3.0L Supercharger Project [Re: 87Montero] #725596
05/25/06 11:56 PM
05/25/06 11:56 PM
FrankR  Offline OP
Web Wheeler
Joined: Feb 2004
Posts: 10,238
Columbia, SC ****
Before you guys come to visit or want to have a copy of this thing, it'd be smart to see if it works <img src="/forums/images/graemlins/lol.gif" alt="" />.... kidding about the visit part - you're welcome anytime. On whether it will work or not... who knows - my SWAGS say "yes, suh", but I won't know for a while.

I haven't seen any evidence of another longitudinally mounted 3.0L with a Roots blower... there are several transverse mounted examples, but none fore'n'aft.... someone may have done one, but I can see why this appears to be the first.

Les - I'd love to have a CNC machine, but I'll be using an old Bridgeport mill.... complete with a terrific retired machinist shop owner/operator who now builds hot rods for a living. Next time I'm at the shop, I'll take a picture of his latest '40 Ford project with a blown mega block. <img src="/forums/images/graemlins/kewl.gif" alt="" />

OK, the S/C outlet plenum is a box type that sits on top of the flange shown previously. The finished product will be milled as one unit from a chunk of aluminum, but for mock up purposes, I'm building it in pieces. The finished plenum won't be this large, but I'm not certain exactly where the S/C will be mounted - so, I've made it oversized and will trim the prototype plenum to a smaller width/length after the ideal S/C mounting location is known. Here's the plenum floor attached to the lower intake flange spacer:
[Linked Image]
The front has extra overhang in case I run into intake clearance issues at the firewall and need to move the blower mounting forward:
[Linked Image]
In this rear view you can see I ran into interference with the coolant lines. I'll correct that later:
[Linked Image]
The plenum will have a 1.50" interior height dimension for good air flow, so I've spaced up all around to provide a mount for the S/C plate. The front spacer is further rearward than the front wall of the plenum will be... it's just for support now until the exact dimensions are known:
[Linked Image]
[Linked Image]
Now the S/C plate piece is mounted to complete the roughed-in box plenum on which the blower will be mounted:
[Linked Image]
[Linked Image]
[Linked Image]

That's all I can do for now until I receive the S/C prototype. It was shipped yesterday from CA, so maybe it'll be here by this weekend and I can hopefully have a little more fun.

Frank

Last edited by FrankR; 05/26/06 01:41 AM.

'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum
Re: G-Raider 3.0L Supercharger Project [Re: FrankR] #725597
05/26/06 12:26 AM
05/26/06 12:26 AM
Tag  Offline
Roll Me Over
Joined: Jan 2001
Posts: 3,876
Oakwood, IL *****
Quote
That's all I can do for now until I receive the S/C prototype

[Linked Image]

How did you order a prototype? You just called and said Hey I need a supercharger for a 3.0? Or did you actually know some specs and give it to them? Will it have internals or will it just be a shell?

Since this will not be a cheap project I see people have already donated parts. Maybe you can put up a list of other parts you need since you are a pioneer maybe even more people can help. Now that I say that I cant think of too much I have but maybe I will think of something or others will.

Either way good luck and cool project <img src="/forums/images/graemlins/kewl.gif" alt="" />.

One last thing how much boost is your goal?

Re: G-Raider 3.0L Supercharger Project [Re: Tag] #725598
05/26/06 12:46 AM
05/26/06 12:46 AM
FrankR  Offline OP
Web Wheeler
Joined: Feb 2004
Posts: 10,238
Columbia, SC ****
Quote
How did you order a prototype? You just called and said Hey I need a supercharger for a 3.0? Or did you actually know some specs and give it to them? Will it have internals or will it just be a shell?


I've done a Helluva lot of homework and in the process I've made a few friends - at Bell Engineering (Corky Bell) and some technicians at Magnacharger who are very helpful. Magnacharger is sending a shell MP62 for me to use to do the prototype work. I paid them a $400 deposit to be credited against a new MP62. I need the shell unit to locate the correct mounting position and determine the correct nose drive length.

Thanks for the suggestion, but I don't think I need any more parts. Most of what I need other than stock stuff will have to be made from scratch or store-bought.

Quote
One last thing how much boost is your goal?


That's a misleading term, since boost is somewhat dependant on flow restriction. As an example, if you plug the exhaust, you can build a lot of boost in a hurry - even with a small blower. The better the engine flows air, the less the amount of apparent/indicated boost as measured by manifold pressure. One way to think of boost is available pressure to force air into the cylinders, but another way is to think of it as the amount of restriction to efficient air flow relative to the S/C output. That said, in everyday lingo, I'm looking for 6-8 lbs of boost which should be achievable with the MP62 on a 3.0L without heating the charge air too much. I've considered using an MP90, but I'd have to slow down the pumping rate by using a larger pulley if I want the engine to last - which would also slow down the onset of power. The trade-offs on blower maps are mind-boggling.

I'm not trying to build a race engine - just have a little more power without fear of blowing it to pieces. Maybe if this one works, I'll try an MP90 with mega boost later on a "built" engine.

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum
Re: G-Raider 3.0L Supercharger Project [Re: FrankR] #725599
05/26/06 01:46 AM
05/26/06 01:46 AM
LRJ4x4  Offline
Web Wheeler
Joined: Dec 2001
Posts: 11,725
Monterey, CA *****
You will do fine with the Bridgeport as we all know it's the operator not the equipment <img src="/forums/images/graemlins/kewl.gif" alt="" />

What a fun project, thanks for the pics <img src="/forums/images/graemlins/cheers.gif" alt="" />


98 Montero with cold weather package
96 Toyota Land Cruiser, fully locked Mall Machine :-)
Re: G-Raider 3.0L Supercharger Project [Re: LRJ4x4] #725600
05/26/06 02:39 AM
05/26/06 02:39 AM
fasteddy  Offline
Web Wheeler
Joined: Jan 2001
Posts: 13,649
Helen , GA *****
Quote
The trade-offs on blower maps are mind-boggling.


Just like turbo maps....

I've done some preliminary pipe placement via the old eyeball, and a turbo 3.0 may be ready by the time you are. Same boost targets. Pinks may be excessive, but I'll put a up a small bottled wager. 1/8th mile to keep the terminal speeds down? Or just trade G-Tech numbers?

Do you have any baseline runs on the stock motor?


Not responsible for advice not taken...
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