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Discussion Starter #41
A few photos:

Apexi RSM, power fc and hks boost gauge installed:

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Heat exhanger and Bosch 010 water pump:

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New Nav/gps/DVD head unit:

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Engine all installed ready to run: just needs to have exhaust done and then it's off for a tune:

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Discussion Starter #43
Well she is up and running, a few minor issues to sort out but overall drivable. I've just got it back from having exhaust done, in the end I got a new custom 4>1 tuned length system built from scratch. I also got the chance to fit my front upper, lower and centre braces. I also sourced a genuine hard top but haven't fitted it yet and want to paint it first; red or black?

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Discussion Starter #44 (Edited)
A few more shots

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Headers before painting and fitting:

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Now I need to find a good tuner, there's some occasional detonation under load and I don't want to blow anything up
 

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Discussion Starter #46
Well after literally years of this car being on the back burner I finally got it tuned, it made 131kw (176HP) at the rear wheels on a Dynapack hub dyno on about 6psi boost.

To be honest I was a little disappointed, the car goes great but I’ve been wanting a bit more from it. I also discovered a few issues that wouldn’t have helped, several boost leaks and injectors close to maxed out meant I probably didn’t get the most out of it.

About two months ago I decided to pull it all apart, make some improvements and tidy up some parts.

I’ll start posting some photos of progress below
 

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Discussion Starter #47
Started with a compression test, all came in between 220-230psi which I was happy with.

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Next step was pulling motor and box out:

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Here is one of the culprits, left this small vacuum port venting to atmosphere since doing the install :rolleyes:: 8DF76B48-DBBE-4A73-B105-FC2EE9FAA475.jpeg

I figured the best way to get more out of this setup would be to raise the boost. Initially I was thinking of just putting a smaller pulley on the supercharger, this isn’t easy on a clutched SC but I had a corolla air con compressor lying around that had a smaller similar looking clutch and pulley on it (standard Blitz parts on right, smaller aircon stuff on left:

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I’m pleased to say after match machining, customising and spacing I managed to get the smaller pulley to fit, here’s the original held up to the now mounted smaller pulley:

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Discussion Starter #48
I realised that in order to raise my boost level enough, I would need to also increase my crankshaft pulley diameter. I ran some calculations for RPM, boost level, supercharger capacity etc and settled on an approximate size I needed the crank to be. Initially I had bought a 2ZZ alloy underdrive pulley kit which was supposed to have a standard dia. crankshaft pulley and larger alternator/WP pulleys, turned out the crank pulley was smaller which would be utterly pointless for me (supercharger spinning slower = :cry:)
Earlier in the project I had decided to press the alloy part inside my factory pulley to get it back to stock size yet save weight; whilst this did work well, it wasn’t going to be adequate so the search was on for a bigger crank pulley.

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In the end I found a late model RAV4 pulley which had the right diameter for my goals and almost the right specs elsewhere: runs on oil seal the same, same offset, just slightly bigger hole for crank snout by 1mm. Not deterred, I got some .4mm shim stock and made a spacer to essentially make the crank pulley a snug, centralised fit. Problem solved, perfectly even.

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The only other issue was the timing mark on the timing chain cover was in the way, so I ground it off, TIG’d up the hole and problem solved.

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All sorted:
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Discussion Starter #49
While the engine was out I decided I wanted to tidy things up a bit, including the wiring (covered later) and making the engine look good. Long story short, I lot of effort went into polishing the entire engine and gearbox assembly, particularly the rocker cover:

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Most other items in the engine bay have either been removed or painted, including painting the engine bay plus rear subframe, engine mounts etc. The engine compartment was dirty and had a few scratches plus ‘massaging’ work for supercharger clearance, I decided to tidy that up then paint:

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The ogura supercharger can only spin to 11.5k rpm a 3.8 inch pulley already spins that dangerously close to the 11.5k

You want to make more power? Put a bigger inlet on the supercharger to allow the air to feed in.

Also that shim on the pulley shaft is a in a bind trick, I would never rely on it to last before the pulley started to develop a wobble.
 

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Really glad to see an update on this! When I eventually get around to starting my blitz SC build (I stare at the box on my living room floor every day) I will likely be bothering you often. Very curious how that smaller pulley works out for you.
If this pulley ratio does give the ability to overdrive the SC beyond it's limit, one can always just lower the engine rev limit a bit. I'd say couple more PSI through the whole rev range is well worth losing 300-500rpm off the top end.
 

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Wow I remember this thread haha good to see you still have the bug. The polish looks nice. I was going to do the same but was intimidated by the amount of work haha


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Discussion Starter #53 (Edited)
The ogura supercharger can only spin to 11.5k rpm a 3.8 inch pulley already spins that dangerously close to the 11.5k

You want to make more power? Put a bigger inlet on the supercharger to allow the air to feed in.

Also that shim on the pulley shaft is a in a bind trick, I would never rely on it to last before the pulley started to develop a wobble.
The TX12 is rated to 11,000rpm continuous and 14,000rpm intermittent. I am running a 147mm crank pulley (up from 127mm stock) and 92mm SC pulley (down from 100mm). At 8600RPM crank speed the supercharger 13,741RPM. I don't intend sitting on 8600RPM, infact I like to keep under 8k even with the new cams and springs which I'll get to later. The TX12 with the standard setup (127mm crank, 100mm sc) would spin at 10,900 at 8600RPM crank speed.

I was aiming for 12psi boost, I've seen .8BAR on my boost gauge yesterday so pretty happy with that. And hey, if the TX12 gives up I'll go turbo.

Re the pulley, I respect your opinion but I'm quite happy with the fit. It is more snug than many OEM pulleys I remove from various makes/models of cars I work on, and the crank pulley bolt is very tight. The pulley still sits snugly against the timing chain gear behind it so shouldn't be wobbling around regardless. It spins smooth as silk even at high RPM
 

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Discussion Starter #54
Really glad to see an update on this! When I eventually get around to starting my blitz SC build (I stare at the box on my living room floor every day) I will likely be bothering you often. Very curious how that smaller pulley works out for you.
If this pulley ratio does give the ability to overdrive the SC beyond it's limit, one can always just lower the engine rev limit a bit. I'd say couple more PSI through the whole rev range is well worth losing 300-500rpm off the top end.
Sweet as, Happy to help
 

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Impressive work, and glad to hear it's running already. If your crank pulley holds up to the test of time I will likely be attempting the same after initial install is functional. First to see if charge temps can be kept in check with only with meth injection and no intercooling...
 

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Discussion Starter #56
Some more new parts recently arrived:

Greddy thermostatically controlled oil cooler and sandwich plate:
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All mounted up in the path of fresh air from RH scoop:

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Mishimoto thermostat arrives:

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Clutch was failing even with heavier pressure plate and new genuine friction disc. Ordered lightened flywheel, 6 puck clutch and HD pressure plate from XTD - I may live to regret this!



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MWR stage 2 cams, HD springs, highflow waterpump and more:
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Started a brake upgrade too, EBC yellowstuff pads and znoelli slotted rotors all around:

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Discussion Starter #57
Out with the standard valve train and in with the new
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Much like the factory 2zz this extra capacity blitz alloy one has always bothered me that it has no baffling...
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Good time to add a trap door and splash plate, just needed a slight trim of the stock windage tray and it was right on:

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Surprising clean ports:

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Do you yank your drivetrain out twice a week or what? Also, have you done anything to the bottom end of this engine? I don't recall reading if you did. 0.8bar might be kinda hard on a stock bottom end.
 

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Discussion Starter #59
Do you yank your drivetrain out twice a week or what? Also, have you done anything to the bottom end of this engine? I don't recall reading if you did. 0.8bar might be kinda hard on a stock bottom end.
Stock bottom end, I’m feeling okay with that as 11-12 psi is unlikely to harm it on its own, it’ll be detonation/lean conditions that kill my ring lands or put a hole in my piston and I have plans in place to avoid that
 

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Discussion Starter #60
Redesigned the w2a setup, have relocated the intercooler to behind the gearbox (major PITA) and replaced all the hoses and fittings with better items plus added a reservoir and re-routed hoses and made items more secure:

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Exhaust was always a bit too quiet, seemed a good time to replace the stainless muffler with a resonator and repaint in VHT black:

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