Open Source Electric Supercharger

[neutron256]

Here is a link for a large collection of compressor maps. Great for researching which compressor to select.

http://www.not2fast.com/turbo/maps/all.html

[neutron256]

My Aquastar T20 arrived today. It's massive compared to the tiny SK3 8S 1500KV.

It will be interesting to see which of these will work better, or if either will end up meeting my needs.

Here are the two together for comparison. The Aquastar's. cooling jacket is removed and sitting behind it.

[neutron256]

Another potentially good line of motors. I'm especially interested in the Toro X8PT 2D. It seems to be very close in specs to those being used in the Phantom design.

http://www.skyrc.com/index.php?route...product_id=152

They don't seem to sell them in the US, but you can get them off eBay.

I need to figure out a more universal motor mount so I can test different motors more easily.

[neutron256]

I tinkered with my design a little more this evening. I was really unhappy with how far away the motor sat from the mounting plate. This was even worse when I swapped in the larger motor.

I redesigned it eliminating the separate shaft and mounted the compressor wheel directly to the motor shaft. Overall I think it's a much cleaner simpler design.

This does require machining the motor shaft which is tricky but I have a couple of ideas about how to do that.


Thoughts/Comments?

Small Motor

Large Motor

[nonicname]

what exactly are you rapid prototyping and what type of plastic are you using?

[neutron256]

Originally Posted by nonicname

what exactly are you rapid prototyping and what type of plastic are you using?

At this point I'm pretty much done with 3D printing. I was just to testing my dimensions for the backplate of the compressor. Once I'm happy with my design in CAD I might do one more print to test fit the whole assembly before I machine the backplate.

I'm using PLA in with a MakerBot Replicator 2.

[SloS14]

Awesome progress!

[djdnz]

Why are you machining the motor shaft, is it too long, or just to add a thread inside? Is the bolt and washer you are showing in the image the method of securing the compressor wheel?

[neutron256]

Originally Posted by djdnz

Why are you machining the motor shaft, is it too long, or just to add a thread inside? Is the bolt and washer you are showing in the image the method of securing the compressor wheel?

The motor shaft has an 8mm diameter, and the the hole in the compressor wheel is 6.5mm. I'll turn most of the shaft down two 6.5mm to fit the wheel leaving a shoulder for the bottom of the wheel to land on. I'll be tapping the end of the shaft so the bolt can clamp the wheel between the shoulder and the washer.

I may machine the spacer/washer so it will also have a shoulder and fit part way into the hole in the wheel.

Here is an better view of the shaft/wheel assembly.

[amird]

I thought couple month ago to start build Electric supercharger same like you.
When I saw this thread I registered to this forum and started to follow after it everyday.
I learn from your knowledge and I wish to help you (if i can) to make this project to success.
Great progress!

[nonicname]

Originally Posted by neutron256

At this point I'm pretty much done with 3D printing. I was just to testing my dimensions for the backplate of the compressor. Once I'm happy with my design in CAD I might do one more print to test fit the whole assembly before I machine the backplate.

I'm using PLA in with a MakerBot Replicator 2.

is your goal to use the prototyped parts just for test fitting or as the actual part? I don't trust those parts holding up to any stress.

[neutron256]

Originally Posted by nonicname

is your goal to use the prototyped parts just for test fitting or as the actual part? I don't trust those parts holding up to any stress.

Correct the 3D printed parts are just to test the fit and get an overall feel of the design. There will be far too much heat and stress on the backplate to make it out of plastic.

I'll be making the actual backplate out of aluminum on a CNC mill.

[neutron256]

So I'm getting close to ready to machine my first backplate. I went ahead and did another 3D printed back plate to test the fit of the large motor and everything is looking great so I had to share.

This motor looks/is huge, but since this is a proof of concept I'm starting big and will see if it can be scaled down later.

[BRS]

[ame="http://www.youtube.com/watch?v=U81_0waqEWA"]Leaf-Blower Supercharging a 1978 Chevrolet Monza Spyder! - Roadkill Episode 16 - YouTube[/ame]