SUPERCHARGER

[MANDALAY]

Have my spark plugs in
NGK
BKR7EVX-11
Also
My Walbro pump.
Next hope you dont think im a freak, but in the pursuite of that OEM look.
My piping is going to be all aluminium cast. Im making the moulds as we speak.
I cant believe how cheap it is if i make my own moulds. $50 a pipe , dame just a bent pipe with silicon is four times dearer and doesnt look OEM.
In the moulds ill also make mounting locations to factory spots, sensors. BOV etc.
The other most important aspect is that it can be reproduced for anyone else
The Rotrex bracket however is being CNC'd as it would require more complicated moulds

[MANDALAY]

Also with the help of mr220v im making a patch cord set up from the harness to the ECU so that way the MoTec can be installed without cuting any of the harness.
The big bonus is also the ease to unplug, and return back to factory in seconds

[puretone]

Originally Posted by MANDALAY

Have my spark plugs in
NGK
BKR7EVX-11
Also
My Walbro pump.
Next hope you dont think im a freak, but in the pursuite of that OEM look.
My piping is going to be all aluminium cast. Im making the moulds as we speak.
I cant believe how cheap it is if i make my own moulds. $50 a pipe , dame just a bent pipe with silicon is four times dearer and doesnt look OEM.
In the moulds ill also make mounting locations to factory spots, sensors. BOV etc.
The other most important aspect is that it can be reproduced for anyone else
The Rotrex bracket however is being CNC'd as it would require more complicated moulds

you mean molds for the pipes between supercharger and intake? Blazin.....
Seems making your own molds for everything is a popular thing down under, John Britten did it...for pretty much everything on his bikes

[puretone]

Originally Posted by MANDALAY

MoTec has control oarameter and accessories to the enth degree So a lot of sensors will be put in for immidiate use and also future.
The other good thing about the ROTREX is that it is self contained. It has its own oil system with resevour. Its not piped to the engine at all. Easy to check oil level. Im over killing it with a fan forced Setrab oil cooler and fitting it to the side air intake.
The Rotrex run colder than any turbo as its not connected to the exhaust and also in my set up its on the intake side.

I think it's a good idea....I would watch the oil temps for operating temperature tho, do not over-cool it tho, it would just thicken the oil up and loose lubricating effectiveness...
Check and see if you can somehow get it to work in concert with the trunk fans? Perhaps with a stealthy duct running to the cooler so it pulls air thru it?

[MANDALAY]

I positive the engine bay sensor comes in at 62 degrees celcius. Im setting the rotrex oil sensor also at 62 so the fan comes on for both the oil cooler/engine bay.
The oil for the rotrex not only cools what ever heat is generated but its also used as traction not lubication so the colder the better

[puretone]

Originally Posted by MANDALAY

I positive the engine bay sensor comes in at 62 degrees celcius. Im setting the rotrex oil sensor also at 62 so the fan comes on for both the oil cooler/engine bay.
The oil for the rotrex not only cools what ever heat is generated but its also used as traction not lubication so the colder the better

traction?! wicked, didn't think they were gonna be badass like that, i figured it was just centrifugal from the belt drive....

from turbo's i know those suckers spin up the better part of 100.000RPM and need lots of cooling on the bearings etc, not just from exhaust heat but from the heat generated from the spinning

I guess yousa fine then with cold oil, but still would be totally badass to have an OEM looking casting of some sort of duct running to/from the oil cooler hehehehhee

[MANDALAY]

The Rotrex spins at 100,000 also

[MANDALAY]

Hey do you guys want me to post pictures of moulds im making and how to .........
For the casting of the aluminium parts ?

[puretone]

Originally Posted by MANDALAY

Hey do you guys want me to post pictures of moulds im making and how to .........
For the casting of the aluminium parts ?

YES GOD DAMN IT, POST EVERYTHING ALREADY

[Edophus]

Originally Posted by puretone

YES GOD DAMN IT, POST EVERYTHING ALREADY

what he said

[Lion_HUN]

Yes, sure!

[MANDALAY]

1 Ok this is how i start. First shape in MDF the part on how i want it. You can see the layers of MDF i used and glued together.

2 Next i file it down so it with an even diameter. Note this is the final shape inside the cast. I paint it in epoxy so when l spray the wax it will remove from the mould easily

3 This is the part that will be the intake to the Rotrex. As such already sanded and awaiting epoxy coat

4 Then i make a box so the above part sits in it so as l can pour a 2 pac epoxy casting resin

5 This is with the part sitting in the box

6This is with the casting resin in and slowly going off. To the left you can see it going white as it sets

7 The same thing had to be done with the other half but in reverse.
The inter pipe is then removed , then the cast is taken out and sanded down to the final shape of the outside

8. These pieces will be taken to the foundary from which he will sand cast then and finally make the aluminium part.

Once its back ill show you the final photo.
Then its of to be CNC'd the ends . One side for silicon pipe and the other side for the restrictor and intake of the ROTREX

[Lion_HUN]

[Edophus]

nice work

[puretone]

very very very sexy indeed!

[MANDALAY]

Thanks guys

[MANDALAY]

My precooler from Rogue is in. It take a photo of it for you. Its very well made, and i pre ordered it in BLACK. Only a slight problem for me. Most of the World had air con as a factory included item. Where as here even though most people ticked the box the air con is add to cars here in Australia before delivery . So therefore one of the pipes that exits the air con radiator is slightly different and doesnt let the Pre radiator to mount in position 100%. So ill unfortunatly will have to make 2 more brackets.
For all USA cars , Turbos you should have no problems.

[puretone]

Originally Posted by MANDALAY

My precooler from Rogue is in. It take a photo of it for you. Its very well made, and i pre ordered it in BLACK. Only a slight problem for me. Most of the World had air con as a factory included item. Where as here even though most people ticked the box the air con is add to cars here in Australia before delivery . So therefore one of the pipes that exits the air con radiator is slightly different and doesnt let the Pre radiator to mount in position 100%. So ill unfortunatly will have to make 2 more brackets.
For all USA cars , Turbos you should have no problems.

OH BOOHOO! LOL!

The whole fun of a custom build is to make brackets and such so as to make it look all custom fitted and stuff....
Yet another great time to make a custom casting for a bracket....hint hint hint hint....

[RST]

I positive the engine bay sensor comes in at 62 degrees celcius.

...another dumb-ass question for you:

Which sensor kicks in at 62oC please? My engine bay temp sensor comes in half that and turns on the side fan. Gonna set my Spal fans for less than that also hopefully based on IAT rather than bay temps. I think I've missed something somewhere.

...so the rotrex is fine on it's own separate cooling circuit -OK. I forgot it's basically a rotary blower (a turbo) -but without the exhaust impellor but essentially a pulley and gearbox.

Moulds for the casting look sweet! Just one question -it's larger at one end. Could that not be done by flaring an ali pipe at one end -can get that done on ali pipe relatively easy over here in comparison? Man, if you can get castings made cheap then go for it -something like that through my engineering sources would be mega bucks. If they're doing it in lost wax castings off that just make sure they can repeat it please!!!

Yet another great time to make a custom casting for a bracket....hint hint hint hint....

...trust me, your MDF plug's alone look a better job than one of the pre-cooler nay whole charge cooler installs I saw by a "pro MR2 tuner" garage in the Uk earlier this year!!!!

Just some more DIY 205 charge cooler install "guff" for you. But some of the MR2 guys comment they have to route their charge cooler pipes under e.g. outside the plastic undershields of the car to the pre-cooler (where it's pretty exposed IMO). I never understood why -but I think they're using cheap nylon cross-braided plastic pipe, or garden hose pipe! Probably useless comment -but I never saw why thin walled alloy tubing wouldn't fit inside the centre tunnel -there's just enough room. Worth investing in a 20mm or so pipe bender to do a good job, rather than rely on soft hoses for me.

[puretone]

Originally Posted by RST

I never understood why -but I think they're using cheap nylon cross-braided plastic pipe, or garden hose pipe! Probably useless comment -but I never saw why thin walled alloy tubing wouldn't fit inside the centre tunnel -there's just enough room. Worth investing in a 20mm or so pipe bender to do a good job, rather than rely on soft hoses for me.

might be an accessibility thing no?


flaring a alu pipe is great, but defeats the OEM cast look I guess. Personally I do not much like flaring alu pipes, had to do a bit of it for my intercooler install to match sizes. The flaring went fine for the most part...developed cracks at the flares over time tho....and we did do the flaring properly...