ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/07/26 18:43:31
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BTW: A bit on an explaination - the thing on the RHS is the vaccum pump for the brake booster. With the 276 degree cams I have pretty much no vaccum, so this was shipped from the USA. Now I have 20"of vac all the time and the wilwoods are very useful!...
The serial cable is just that - connects to the ECU, this would normally be tucked away but the car has just been to the tuner to sort out the idle and cold start (which is great now)...
the black cable is the fuel release. I have made the boot release electric (remote too), and I am going to do the same to the fuel release... THe Viper security system has a few AUX functions so boot is one and fuel is another....
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/07/26 18:58:57
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Another post .... Sorry if I am boring you all..
I am sure I am not alone, but I have been a bit worried about the possibilty of breaking one of the targa panels ! - anyway, I found a set on ebay in the USA and bought them. They arrived today and to my shock! were in one piece!!! I thought I would have a box of a million pieces..
They are different though - in a good way, they have locks !!! (see picture) ... Do others have locks or is this a USA model thing ??? (didn't come with keys though so I will have to get them cut.)
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/07/31 23:13:05
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Isn't it amazing how things turn out ! ..... I spend a weekend a couple of weeks ago replacing the water pump with and electric one so I could get more 'wrap' on the supercharger as the belt was slipping at 6000 rpm (16psi) after a weekend of work where I also relocated the BOV, and added a Bosch idle control valve, I was disappointed when the car only made 10PSI.. and felt like a sloth!.. It also rattled a bit on idle which I put down to the idle control valve slapping shut.
Took it down to Bullet supercars (rotrex dealers) on Saturday and they could not see anything obvious - suggested a dynamic tensioner (which I bought), and maybe a 6 to 8PK belt ... which is a massive expense as pulleys are really expensive to have made, and I would need to move the alt and air Cond compressor...
On Sunday I decided to look at the intake pipes to see if they had cracked and on removing the inlet pipe to the supercharger was shattered when a 10mm 1/4" drive mangled socket fell out !!!! - It somehow fell into the 1.5" hole for the BOV vent return.. Can you believe it !!!.. check out the photo of the turbine! - it shouldn't look like that!
SO thats $3K down the dunny ...
What happens now ... well I have ordered another rotrex, but this time I have upped the size to the big daddy ! .. Bullet took sympathy on me and gave me a good price!... I will pop down on Sat and get it..
I also need to relocate my SC oil cooler from on top of the engine with heat exchanger so it will go down under the car, I have got PWR to make me a new larger heat exchanger that will be about the same size as the original intercooler.
I will pop the engine out and sort this all out, I want to set the cams (very accurately) laser align the Supercharger pulley, check the water pump blanking plate as i think it may be ever so slightly leaking, and re-loom some wiring.. Might even send some stuff to the chromers, and replace the rubber pipes with braded - make it look blingy ..
this car is a money pit ... could have bought 2 new Toyota 86's for what I have spent! but added together they still would not have as many ponies as my AW
stay tuned .....
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artymr2
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/01 00:37:11
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Black SW20 GT Turbo T-top 
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stuka
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/01 18:43:48
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thats rotten luck, can you not just replace the turbine?
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/01 19:23:34
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Not recommended ... the housing is a bit 'chewed' up too .. a good excuse to up the size to a c80-94
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Doctor
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/01 20:19:20
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I'm missing a 10mm socket. Can I have it back please? 
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/01 21:53:25
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ha - at least I have a full socket set now....
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Knightrous
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/01 22:50:12
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I'll give you $50 for the damaged Rotrex ;)
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/04 11:24:58
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This is what the SC should look like ....
This is th enew C30-94 that is going in - look at the difference in turbing diameter! ...
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bustin
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/04 15:46:53
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wow. shows how much the other one got chewed up. keep up the good work, can't wait to see/hear this thing go.
What we're dealing with here is a complete lack of respect for the law.-"Sheriff Buford T. Justice." Do you know the 1st rule of Italian driving?
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/08 08:28:13
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☄ Helpfulby Minty AW11SC 2013/08/27 06:11:02
Engine Out and no going over doing all those things you try to do but fail when it's in the car! ... It's so easy to do things when its out !! Jobs: - Fit new Supercharger
- Laser align pulleys
- Fit dynamic tensioner
- Dial in Cams (properly)
- Relocate LS2's from being attached to engine to firewall
- re-route wiring
- BOV re-location
- ABV for idle control - re-locate
- Weld up thermostate bypass pipe exit (No need for this with electric water pump)
- fabricate waterpump blanking plate (replaces water pump)
- New heat exchanger from PWR (removed the supercharger oil cooler from it)
- relocate supercharger oil cooler to bottom front of engine bay
- relocate engine oil cooler to beside supercharger oil cooler
- fabricate air deflector for coolers
- polish and anodize cam covers
- polish all allow pipework
- replace rubber hoses with stainless braided stuff
I think that is enough ... and all this to be done by the weekend..
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Doctor
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/11 10:00:22
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When can I come over and check it out? 
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/08/17 08:22:40
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Well the engine is back in the car after ticking all the to-do's ..
See pics attached which shows the dynamic tensioner setup and the water pump blanking plate I made up out of 100mm aluminium. Photo of intake pipework pre intercooler installation (BOV).
I also relocated and changed the oil cooler setup for the supercharger. Rotrex recommend the cooler is located lower than the reservoir to prevent the oil draining back into it and overflowing. I never experienced this with the previous setup however, I like things to be right. This setup is based on a larger slimline oil cooler - I built a frame for it to mount under the car, and it has a mesh protector that has been produced in such a way that I am using it as an air deflector also. If I pass air over it horizontally there is a large volume of through flow air – so it should be very effective. I have replaced some of the hoses with better quality, and just cleaned things up a bit.
The cams are dialled in and are as per Kelford specs now.
I also refabricated the idle control. I’m using a Bosch PWM type with 19mm in and outlets. The setup I had before was ineffective as the 19mm was being reduced to 3/8’s at one point and ICV was too far from the throttle body. Now the unit is mounted directly under the throttle body with pretty much no distance and all pipes are 19mm. Result though it the car idles at 4000 rpm ! and hunts up and down (it’s horrendous) . This will be fixed with the next trip to the dyno on Tuesday next week.
I couldn’t help myself and I took it for a little drive – saw 25 PSI @ 7000 RPM. No belt slip, and ballistic .. the computer did pull timing on initial rev, so it may need it’s over boost limit set up a bit higher, If you are in second gear at 4500 rpm then floor it it spins the rear wheels!
I have a new Heat exchanger being made by PWR as I have been able to remove the SC oil cooler from the top mount – so the water to air intercooler should be more effective now too.
I think I may drop the RPM limiter down to 6750 to protect the engine (and me) .. I think I have approached the point of having too much power (if there is such a thing)…
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!) ************ FINISHED *************
2012/09/03 19:24:53
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I think this will be my last post. The project is complete. Another session on the dyno today to dial in the boost control (yep - boost control for a supercharger!!! - we used a BOV that runs equalising pressure from pre throttle body through a valve controlled by the computer) The car run beautifully, idles at 900 without skip or miss, starts hot, starts cold and just works.. It’s been a hell of a lot of work, but is finished… For those people who like figures – we have squeezed 240kw out of this @ 22.5 PSI ATW, 395 nm of torques! Its FKN FAST!!!!!!!!!!!!!!!!!!!! With the boost control, the max boost is achieved at 6000 RPM, and is flat to 7800 RPM . it’s so nice to drive. Fast Fours and Rotaries did a photo shoot of the car last weekend (thumbnails attached) .. The Story will be out in December.. I have read the story and it’s awesome! -they are really excited about having a brilliant little AW11 – makes a nice change from S15’s! Thanks to everyone on this forum for comments, enthusiasm and encouragement! Thanks to Aaron from Lithia Toyota in Springfield Oregon (USA) for his help sourcing parts.. And to David from TwosRus, The final part (rear tie rods) arrived today after ordering on Thursday night last week – USPS Global Express – 3 days to AUS !! I think I will sit back, smoke a cigar and contemplate my next project … hmmm – maybe a Supercharged 6L V8 for my Hummer ! J Check out the final run on the dyno, suck in the pure sound of this little 1.6L blown 4 banger! http://www.youtube.com/watch?v=LO4ByfwHdfk&feature=youtu.be I would love to show it off, so if there are any events or runs in Bris – Let me know… :)
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