Ok so this is where its at.
All was installed.
Everything was checked before going on the dyno.
We had spark, fuel and every senor , motor etc was triggered to see it was operational.
Started with a basic map , adjusted and ran in the engine and the Rotrex supercharger.
Probably did around 100 kms believe me we were on the Dyno for 2.5 days.
Then a stuff up i did was obvious :(

This is it , well initial design and recommendation was for only 7 psi as the engine was going to remain stock.

Well i ditched that idea and went forged internals so as i could go max psi but i forgot that all my pipes that i made were only 42 mm so as to restrict the output of the SC.

WELL THATS WHAT I GOT 7 PSI. My calculations were correct.

So what we did was to see how much it could generate and we took the inlet to the SC off and up went the psi , up to 13 psi but remeber there is still restriction after the SC.

It was only a test. Well my engine will come out tomorrow so as i can update all the piping to 75 mm , 3 inch.

Ive already started the aluminium work , see below.

But i drove her for a few days with 7 psi and i have to tell you its dam, dam fast. The BEAMS engine and the SC were ment for each other.
The characterists of the engine remain the same however it feels as if there are a few more pistons in the back.

It pulls in any gear, and 1st is so fast that you frantically go for second.
As is its easily a 5 second car to 100.
I think the anicipated 15 psi is going to scare the poo poo out of me.

Go easy on the throttle and its just like it was.
Accelerate and it pulls you into the seat right up to 7,600 rad line without any flat spot or any indiation of running out of power. THE MORE THE REVS more the power.

In a word awsome !

Oh well now i know what it feels like i am a happy chappy :)
But its back to the drawing board

So to do the mods first is the water return line that supplies the heater.
It had to be shortened to allow the 3 inch line

This is the bypass water return to the heater which is in the way for my 3 inch line.
So with another pipe i had it shortened and a u return welded on.
This way all ill have to do is shorten the hose so as not to make a new one.





and now just make the line.

For those who havent seen how i make them here is the process

This is the pipe exterior, 3 inch line that will feed the Rotrex.I turned some pine to the correct diameter , used a little filler then sprayed it with filler

Now ill make the inner diameter of the pipe and then pour urethane in between.



Just a pic to show the difference with the previous mould

[URL=http://img816.imageshack.us/i/dscf7299.jpg/]

First made a box out of MDF , put the outside pipe profile in and poured the silicon rubber



This is the rubber sections



This pic shows the inside profile of the mould ready for the urethane to be poured.



This is the urethane poured



This is with the pipe removed



This is the final piece removed from the mould.
As you can see the are quite a few steps in making the piece.
Either way i have permanent moulds to make them again.

They need to be final sanded , machined and then powder coated.



So here is the aluminium cast of the above mould.
Came out great.
On to the next piece. Long process but i enjoy doing it.
Now it of to the machine shop.



3 inch line. Now roughly 2.5 times bigger than the first one i did. Surely now it wont be restricted

This is the mould finished for the distribution of the air from the air box





This is the cast piece.





Of to the machine shop to CNC the openings and make it perfectly square.
Then ill put a lot of hours filing and sanding it down.

The new version is 3 inch ( 76 mm )diversion to the Rotrex SC.
Whereas the post intercooler is 2.5 inch ( 63 mm ) then expanding to 3 inch to the throttle body.

Much bigger than the original 42 mm as you can see

quote:

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Originally posted by MANDALAY

So to do the mods first is the water return line that supplies the heater.
It had to be shortened to allow the 3 inch line

This is the bypass water return to the heater which is in the way for my 3 inch line.
So with another pipe i had it shortened and a u return welded on.
This way all ill have to do is shorten the hose so as not to make a new one.

[URL=http://img408.imageshack.us/i/dscf6383.jpg/][IMG]

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Ahh, another miracle from the blessed Mary, the return of MR2 porn...

Oh BTW for the power freaks . At 7psi it was 220 HP at the wheels.
Still on the same tune and really out of wack just to see the gain without the restriction it went up to 275 HP at the wheels.
320 - 350 will be a realistic figure once finished put the power is a straight line straight up to 7,600 with no leveling

So at 7 psi its got as much as a factory GEN 3.

That is soooo awesome! You never cease to amaze me/everyone on the forum!

I love all this fabrication, get it done before the hill climb on December 5th:)

When I want to show my friends an immaculate MR2, I always show them yours in terms of modification that doesn't scream for attention. It all looks so factory.

Good to have you back on here Angelo

+1 on the fabrication work!