Full throttle Electric Supercharger Build Thread

[Qwimby1]

My Borla header and Werks free-flow cat front pipe made a noticeable difference, but I was already running E85 by then. If I had a gen 2 I would probably consider a real SC, but mine has a build date of 1-14 and I suspect that engine is not as robust as later models.

[Qwimby1]

Originally Posted by WNDSRFR

Yeah
E85 is nice. There's one station 25 miles away I used to get it from when I was working. I would pass it every day. But now it's 25 miles away. Not worth it.

And you think it would be bad with an ESC and no E85? Try driving with neither after having either one or the other or both for nine years. It's a little hard to get used to no torque at all.

Yeah, I have to agree with the "this car is slow" folks. Because it is.

So do you have your ESC back together and working now?

[WNDSRFR]

No
It's still at the machine shop. Going on a month now. I dropped it off on a Friday. Gave them a week unharassed. Called them the next Monday and they didn't know what I was talking about. Turns out I went to the wrong shop. The right one is down the street. So I went to the shop I left it at and the guy says "Oh he's on vacation this week." Well I wish he would have told me that. Next week he was too busy on other things. Next week there's a hurricane. Called them yesterday and he said he would do it tomorrow. Well, now tomorrow is today.

I'm getting tired of this. Why is it so hard to get anybody to do anything anymore?

[Teseo]

Originally Posted by WNDSRFR

No
It's still at the machine shop. Going on a month now. I dropped it off on a Friday. Gave them a week unharassed. Called them the next Monday and they didn't know what I was talking about. Turns out I went to the wrong shop. The right one is down the street. So I went to the shop I left it at and the guy says "Oh he's on vacation this week." Well I wish he would have told me that. Next week he was too busy on other things. Next week there's a hurricane. Called them yesterday and he said he would do it tomorrow. Well, now tomorrow is today.

I'm getting tired of this. Why is it so hard to get anybody to do anything anymore?

Because government.

[Qwimby1]

Originally Posted by Teseo

Because government.

+1

[WNDSRFR]

Just a quick observation. If you unplug the connector to the activation switch, it runs continuously. I ran the thing in a vice and it would make one hell-of-a leaf blower. This thing is scary.
I'm putting it all back on the car today. My hopes are high. Let you know how it goes.

[WNDSRFR]

Got it all back together and on the car.
Butt dyno says it works good as new. YAY.
The new modified wheel fit almost perfectly. It fit super tight. Tight enough that it rubbed the housing a bit. My first idea was to just run it and bed it in. But I figured I've come too far to fukitup now. So I painted the housing, spun it, and sanded where it rubbed. The biggest pita was the snap ring that holds it all together. Played with that for awhile. The other pita is mounting the switch on the gas petal. I'll do that later.
Had one casualty along the way. I dropped the machinist's vice on the bumper testing it. Made a nice new gouge.

Anyway, I'll do a log tomorrow morning when it's cooler. I'll record boost, atmospheric pressure, temperature, RPM, and speed.

[WNDSRFR]

I'm declaring it fixed.
Did a third, forth, fifth run and it feels great. Running in 6th gear it consistently hits 4.6 with intake temperature of 89 degrees. Not bad. And it costs less than 200 bucks to fix.
Next up, I'm going to replace the controller fan. I don't usually fix things that ain't broke. But I'm making a special exception for this. By all rights it should have failed years ago.

[WNDSRFR]

Well,
I was right about the controller fan. Maybe it did fail years ago. Or maybe this morning. All I know is it doesn't work now.
The part number is: Gdt 6020s which of course is no longer available.
I ordered a Wathai 6025B12V2P2.5 from Amazon for $8.99. Should be here tomorrow.
Under an abundance of caution I decided to turn it off until I get the new fan.

Just got the damn thing fixed and now I'm going to turn it off.
Jeez

[Qwimby1]

I'll try to trace back your posts and make a list of the parts, numbers and modifications, unless of course you feel charitable and post them yourself. We all owe you a great debt for this blueprint for repair.

[WNDSRFR]

I replaced the controller fan. At first I didn't think it really did anything because the controller gets too hot to touch even when it's off. Just from the heat from the engine. And the way it works is pretty hokey. It blows air toward the controller. It's spaced off by two nuts and blows air into the controller though a filter material covering holes through the box. Very strange. but after driving around for a while, it does stay cool now. So I guess it works.

[WNDSRFR]

Now that I have a basic understanding of this thing I'm thinking about building my own.
I know the compressor is from a Cummins 11 liter diesel engine and I know the spec on the motor. I'm thinking it might be cool to make a 36 volt system. Since the motor speed is directly proportional to the voltage, I'm thinking that 36 volts should be good for 75,000 rpm which should be good for 7.5 lbs of boost. I think it would be worth trading some duration for more power. In normal driving I've never run out of boost with 24 volts. In reality you're never going to be boosted for more a few seconds on the street unless you want to go to jail and forfeit your car.

This thing is great. Everybody should have one!

[WNDSRFR]

I found THE motor! Check this out! 85,000 rpm! And these guys will custom build whatever you want!

https://www.tppowerusa.com/index.php...product_id=575

[Qwimby1]

Originally Posted by WNDSRFR

Now that I have a basic understanding of this thing I'm thinking about building my own.
I know the compressor is from a Cummins 11 liter diesel engine and I know the spec on the motor. I'm thinking it might be cool to make a 36 volt system. Since the motor speed is directly proportional to the voltage, I'm thinking that 36 volts should be good for 75,000 rpm which should be good for 7.5 lbs of boost. I think it would be worth trading some duration for more power. In normal driving I've never run out of boost with 24 volts. In reality you're never going to be boosted for more a few seconds on the street unless you want to go to jail and forfeit your car.

This thing is great. Everybody should have one!

I think there would be a market for those. You would be putting out close to the boost of a conventional SC, but at much lower cost and easier installation.
In my case, part of the appeal is the 5lb boost since I have a 2014. I might go for more boost If I had a later model with what I suspect have been several engine improvements, both known and unknown.