Operation Overkill

[Papa Rad17]

I cant wait for that new engine with all of this! cant wait to see new numbers even with what you just did either.

[AleroB888]

Got another intake:

[IMG][/IMG]

[AleroB888]

Mock-ups!
Reconfiguring components for a blow-through intercooled setup. This may be my last attempt at it.

[AleroB888]

painted the steel mount hardware (except half-round tubes, which are an extra set; ones in use now are stainless)





test setup w/ new type stock MAF sensor, BOV/bypass pipe in place.

[Papa Rad17]

Nice

[AleroB888]

BOV/bypass, throttle side

[AleroB888]

about to make first test of concept under some boost. Looks scary, don't it?

[AleroB888]

Completed 2 test drives..... after shortening the cable linkage it finally got 2-3 psi boost. That's almost what was expected for using a rain cap as a valve..... no attempt was made to improve the seal at the mating surfaces. Plus the boost pressure has some leverage to force it open.
But nothing terrible happened on the tests, so now I'll try to come up with a non-leaky valve

Ha, just remembered I forgot to reflash the PCM for the stock MAF

[AleroB888]

I used a throttle body as the BOV (or bypass, or recirculating valve). This one is only 58mm, not 65mm like I think it needs. And it should be mounted closer to the charge tubing.

Got in 3 test runs, blew out 3 different silicone couplers. lol
Made it to 10 psi on the last one. Acceleration from standing start was good, so the method seems to have potential. But abrupt deceleration has yet to be tested.

[AleroB888]

I tightened up the connections and made another test run, and the device appears to work. Floored it from 25 mph, spun the tires and it pulled nicely up to about 60 mph. The charge pipes shifted around some, and then I had to trim the actuator lever on the "BOV."

The throttle response is different than the standard non-intercooled setup was. Sort of like a mechanical secondary on a 4-barrel carb. Since the two throttle plates tip in at different rates, It required a progressive linkage where the primary TB opens about 15 degrees before the secondary TB (BOV) starts to close. That's an adjustment that mainly affects part throttle response. But BOV opens instantly when you lift your foot, with the help of a return spring

I have to admit, this is the scared-est I've been to drive this thing.

[Papa Rad17]

Video? Cant wait to see track times!

[richardg]

Video? Cant wait to see track times!

x2. I'm not into modding for power anymore so I'll live through you guys. Looks great

[AleroB888]

Thanks, guys. This is in the early prototype stage, and still a lot of things to test. I have to make sure it will be safe to operate long-term, and not damage the supercharger. A lot of things will have to change on it before it can race. I've had very little time to take it out for test drives, busy with personal affairs.

The most difficult thing to do on this now is get the noise level under control. In this configuration, the whine and howl from the supercharger is extreme (kind of weird sounding), even with that Fram filter and intake tube muffling some of it. So it's not nearly video-ready.

[AleroB888]

Took a 10-mile cruise and peaked at 12 psi, which is pretty good considering the restrictive warm-air intake tract. But I did have some debris from the blower make it through the intercooler to the MAF screen, and a trace of PCV vapor oil in the intercooler pipes.....(I'll deal with the PCV later, right now it is fed to the blower inlet.)

I put a screen in the pipe from blower to intercooler, and revised the BOV actuator as a self-contained unit.



Then, to make sure outside air is not pulled back thru the BOV under vacuum conditions, I cut up half-inch squares of paper, put them in the BOV outlet, and a screen over that to keep them in. I drove around the block at low rpm, and the paper stayed on the screen, indicating a constant outward airflow.

I haven't had much time for test driving, but it's not fun in this heat anyway. On the WOT runs that I did make, the temp. increase post-intercooler stayed below 20 degrees, even with no water lines hooked up on the intercooler yet. Normally, I'd see a 50-70 degree increase during 0-60 mph runs in this heat.

The blower noise, though, is going to be a huge challenge. It's loud, obnoxious, and almost constant.

[cavedewler]

so is that an extra coolant bottle with the green cap?

[AleroB888]

Nope, in this incarnation it's a washer fluid bottle.

[adrian13]

Nice!!

hmm... you just gave me an idea for the snow meth injector fluid reservoir location with the washer fluid bottle.

Also, I was looking at your configuration for the pcv system. Where does the pcv valve on the front valve cover go too? Also, how's the rear valve cover opening connected to the front or the uim for vacuum?

[AleroB888]

Originally Posted by adrian13

Nice!!

hmm... you just gave me an idea for the snow meth injector fluid reservoir location with the washer fluid bottle.

Also, I was looking at your configuration for the pcv system. Where does the pcv valve on the front valve cover go too? Also, how's the rear valve cover opening connected to the front or the uim for vacuum?

That washer bottle iirc was from a Saab but doesn't quite fit for hoods that use a stock prop rod.

The PCV hose from front cover goes to the blower inlet casting, until I can find a better way to do it. I'll probably tap into the driver's side top of the UIM.

The rear one uses a 90 degree brass elbow and hose going to a small filter in the driver's side of engine compartment (not under vacuum). That's one of the things I hope I get time to finish later.

The intercooler traps a lot of the PCV vapor oil, but I still don't like it going through the blower and having to clean out the intercooler, even though my intercooler does not have to be removed to clean. The MAF sensor, especially, should not be subject to any PCV vapors. I have been taking apart the intercooler pipes every other day to check their condition. Still a lot of things to sort out in this build.

[adrian13]

I hope that the pcv doesn't push oil also through the blower under boost because I think it could mess up the blower too. You should put an oil catch can instead.

I know that there's tons of things you're planning to do with this build. I am looking forward to your seeing how your build progresses.

I am looking to turn the motor over tomorrow for LA1 swapped Malibu. Its the first time in almost 4 years lol. I've been super slow and missing lots of parts with endless trips to the junk yard for misc nuts bolts and lots of wires. I've been a little stumped lately with the mp62 pcv routing. Lots of thinking...

[AleroB888]

Originally Posted by adrian13

I hope that the pcv doesn't push oil also through the blower under boost because I think it could mess up the blower too. You should put an oil catch can instead.

I know that there's tons of things you're planning to do with this build. I am looking forward to your seeing how your build progresses.

I am looking to turn the motor over tomorrow for LA1 swapped Malibu. Its the first time in almost 4 years lol. I've been super slow and missing lots of parts with endless trips to the junk yard for misc nuts bolts and lots of wires. I've been a little stumped lately with the mp62 pcv routing. Lots of thinking...

At one point in the past, I ran the PCV tube from the front valve cover to an aluminum oil cooler in front between the headlights, then routed it back to the blower. The reason I did it then was to keep heat out of the blower, but I may revisit that method. It did trap a lot of vapor, but I did not "invent" a practical way to drain it. Shouldn't be too difficult,though.....