B20 M45 EFI project

[Burdekin]

Any reason why you didn't use a E plenum? And you could use a 850r throttle body for example as well with the plenum.

[granarycottage]

The reason I didn't use a an E plenum: I didn't have one, but more importantly the reason will become apparent when I upload more pictures: the plenum I am building doubles as a intercooler.
as for the throttle body: it will be placed before the charger and is a 55mm Ford RS turbo item, nice clean throttle body, shiny also, I will upload a better pic later

[granarycottage]

After a talk to the specialists at www.bs-autotune.nl I decided to make long intakerunners for low/mid range torque and add a 180 degree bend in the runners.
The straight rummers were made to fit in the cutback plennum and welded in. I use a stick welder and grind down excess weld. lots of work but nice results

[granarycottage]

The inlet manifold is fed by a inlet plenum that doubles as a water to air intercooler. The plenum will be symmetrical fed by a 55mm inlet channel and outputs through 36mm outlets. connection to the supercharger with a 600mm alloy/silicone hose connection, connection to the inlet manifold by 4 flexible silicone hoses of 40mm diameter.
Pictures of intercooler details will follow...

[granarycottage]

first I planned to fabricate an intercooler of copperpipe and lots of washers, a diy laminova core basically. This proved to be possible but much too coarse and heavy. So I decided to use a heater radiator core from a VW polo. It was cut back to the required width and the waterinlet/outlet housing was adapted to fit the narrowed core. The core length was a bit short so I added a bit of left over core to the end, this part will not cool per se but will keep the flow in the plenum consistent for all cylinders.

The plenum outlets will flow a bit better through a ' trumpet plate' I made to suit the inside of the plenum. Not massive trumpet but will flow a bit better than just a cut hole. All will be blended to the pipes by porting as is most of the air intake system and head on this build, pictures to follow.

The plenum half sphere end caps will be removable and will be attached to the plenum body by four taps per end visible in the pics with red background
The intercooler inlet and outlet is also visible parallel to the plenum outlets. Two holes were cut in the back end cap to suit the intercooler connections. Still pondering how to seal these up, possibly just by pouring expoy resin in the end cap and attaching and sealing the intercoorler to the cap in one go... not very serviceable however.
As for the end caps: they fit nice and tight already and a bit of vulcanising tape between the caps and the body will seal it properly.
The front end cap will function as a damper for the vacuum/boost signal to the fuel pressure regulator. To this purpose the end cap will be separated from the main body with intercooler by some drilled plates, tips on how many holes and the size of the holes are welcome....
The plenum inlet is slightly angled so the connection between supercharger and plenum will be short and straight.

[granarycottage]

The intercooler is placed inside the intake plenum. It consists of a narrowed heater core. The end cap of plastic is shortened and welded back together. I will strengthen it with expoy I expect.

The intercooler will slide in the plenum and will be sealed to it by some heat resistant tape or so, siliconed to the outside of the core. I want all airflow to go through the core,not around it.

The last picture shows the front end of the inlet plenum which will be closed off from the rest of the plenum bar a few holes. shown here the mock up of one of two plates to be welded in. It will hold the radiator core and close of the damper chamber at the same time. A few holes will be drilled inthe plates for pressure communication. I use the dampened vacuum/boost signal for the fuel pressure regulator and the boost gauge.

The MAP sensor will be a bosch type screw on type. placement of this sensor is a factor to consider: on the dampener chamber or directly into the manifold between the two middle outlets to cylinders 2 and 3.
Any suggestions?

Details on cool water system still on drawingboard, I have ebayed a bosch electrical water pump soon to be delivered to my workshop after a trip to England in May (I no longer reside in P'boro but visit regularly to pick up ebay shipments, sending stuff to Holland is expensive and not many UK sellers will do so...

[granarycottage]

Now over to the other side of the engine block where the supercharger will be placed. The supercharger manifold will double as its bracket and needs to be sturdy.

Many diy supercharger installs on the web show very weak brackets and I decided to over dimension my build as a result.

Shown in the pictures are the first cardboard mockups.

For the bypass valve I had already decided to drop the electronic valve that came with the mercedes slk compressor. It was going to be a challenge to control it with the edu so I ebayed a mini cooper bypass valve. A lot smaller as well which eased placement on the supercharger manifold(s)

The supercharger outlet plenum used to be the end cap of a bench grinder.
'The person who saves stuff, has stuff' is an old Dutch saying....so true for this build as will become apparent later

[granarycottage]

As the attachment in the first post of this thread has disappeared after the server update I thought I repost that picture. This is pretty much the state right now. Many parts are waiting for me in the UK and will be added after pickup in May.

Parts ordered:
hoses, checkvalves, barbs, Y's, oil catch tank, etc for the crackcase ventilation
fuel rail profile
fuel pressure regulator and fittings AN6
fuel injectors (Bosch ev14, 300cc/min @ 3 bar, 20degree spray pattern, 4 hole)
60mm 90 degree alloy bend for connection S/C manifold to intake plenum
60mm silicone hoses for connecting above
40mm wired reinforced silicone hoses for 180 degree bends plenum to runners
25mm silicone hoses for idle air control circuit (will fit IAC-PWM valve)
flexible oil dip stick, for a Chevy block I believe, curious if it will fit)
and ongoing...

[granarycottage]

After weeks of cardboard templates and mockups I started building in steel. Designing along the way really but sometimes that's better

The supercharger manifold consists of three parts:
1. The S/C inlet plenum connecting to throttle body and bypass valve
2. The S/C outlet plenum doubling as the S/C bracket, connecting to engine intake plenum and bypass valve
3. The idle air control inlet. As the slk superchrger has two inlet channels I use the main one for the throttle and bypass valves and the second one for the idle

All three parts will bolt onto the supercharger using rubber-cork gaskets.

The outlet plenum will bolt to the engine block in three places:
- on the fuel pump attachments - this gets rid of the fuel pump
- using a bolt hole in the side of the block just underneath the head and above the fuel pump
- using a bolt hole beside the water pump

Further attachment of the S/C using a bolt hole in the side of the timing gear guard of the block.

All bolt holes in the block for this purpose have been enlarged to M10.
Total 4 connection points to the block using 6 M10 8.8 bolts. Should be sufficient although I am thinking of enlarging to bolts supporting the S/C snout with M12. Most force will be on them through the belt.

[granarycottage]

Although I am not sure about the colour, I ordered some matt red which will look better I think, I painted all the finished supercharger manifold parts this weekend. Below all parts and valves and a trial assembly of painted parts.

The mating surface on the outlet manifold is shaped to aid air flow and gasket tightness. The manifold was not straight anymore after welding necessitating this step but turned out quite nice.