Supercharged 2GR SW20 Project

[lasersooby]

Hi Team,

I have not posted for a while, too many things going on in life hence no time to upload too many things.

A lot work has been going on in the background. Here is the supercharger setup on the plate intercooler which in turn has been bolted up to the lower intake manifold. Have included the cam covers as well as the 50mm spacer that will be placed between the throttle body and the supercharger and we will tap and install 2 x 2000cc Bosch injectors for the methanol system:

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[lasersooby]

Got stuck into cleaning a lot of the parts before the full engine assembly, especially the cam covers as there was a lot of burnt ol build up under the baffles.

Cam covers (before and after):

[lasersooby]

Cleaned up a few other parts that had a bit of gasket gunk stuck on it when we disassembled the engine:

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[lasersooby]

The dipstick and VVTi solenoids sorted:

[lasersooby]

We installed Motion Raceworks Billet Valve Cover Breathers, this will connect to Radium Catch Cans that are made for for the Lotus Evora application:

[lasersooby]

Engine Assembly update:

Nuts, bolts cleaned and ready for the build and the gasket assembly opened and checked to ensure everything is there:

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Engine block set up on the engine stand, setting up crankshaft and caps, all with ARP bolts:

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Piston assembly, precision gaps for the rings included:

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[lasersooby]

Engine assembly continued:

Pistons in the block:

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Head on engine block, checking for fitment before we assemble the head:

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Head assembly with Kelford Cams - Stage 1, not using any shims as we checked the deck height and sorted that out at the machine shop and the Workshop did their magic that ensures we do not have to worry about the deck height issues that gets sorted by the use of shims:

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Head bolted on to the engine block:

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Sleeping under cover for now, have a few more things to do:

[lasersooby]

Engine assembly has continued and it is getting close to getting completed. It is getting to the exciting stuff now

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Polished w2a plate intercooler top plate:

Engine with headers on and supercharger;

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10 x bearings for idler for the belt routing:

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Polished bearing holders:

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New bearings from Applied Industrial Technologies, Ben is the man to see:

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[lasersooby]

It has been a while since I posted any information on the progress on my build.

A lot has happened, and it is getting closer to getting the engine and gearbox into the engine.

I had my Honda Accord Euro Type-R Recaro seats retrimmed and the door cards done to match. Lawrence Auto Trimming in Tremaine Ave Palmerston North has done a great job. Ross removed the OEM covers off the seats and used that as a template to make new ones for me. We added a bit of color (apparently from the early 90s BMW material) and everything has come out really good, stoked with the outcome.

I just have to get the seatbelt guides sorted (the silicon coating had gone very sticky and were pulling away from the plastic). The plan here is to paint them black which I will sort out soon then back on the seats and we are done ready for the install.

Also, tried out the M+H rails. They are unfortunately too low as the seat sits on the floor, have to make an adapter plate to raise the seats a bit so that they clear the floor.

This is what the old seats looked like:

001 OEM Honda Accord Euro Type R.JPG (123.82 KiB) Viewed 2327 times

002 OEM Honda Accord Euro Type R.JPG (133.17 KiB) Viewed 2327 times

003 OEM Honda Accord Euro Type R.JPG (156.99 KiB) Viewed 2327 times

The issue with the seatbelt guides:

004 Seat Belt Guide Silicon Coating Failure.JPG (1.73 MiB) Viewed 2327 times

005 Seat Belt Guide_Removing Silicon Coating.JPG (2.21 MiB) Viewed 2327 times

006 Seat Belt Guide Removing Silicon Coating.JPG (2.79 MiB) Viewed 2327 times

Removing the old seat cover:

007 OEM Seat Cover Removed.JPG (4.95 MiB) Viewed 2327 times

Heater pad install (back and bum):

008 Recover Seats with Heating Pads.JPG (4.05 MiB) Viewed 2327 times

New covers made for install on seats:

009 New Seat Covers.JPG (5.49 MiB) Viewed 2327 times

010 New Seat Covers.JPG (4.51 MiB) Viewed 2327 times

Recovered seats:

011 New Seat Covers Fitted with Heating Pads Installed.JPG (4.02 MiB) Viewed 2327 times

012 Seat Rear View.JPG (4.24 MiB) Viewed 2327 times

013 Both Seats with New Covers.JPG (3.85 MiB) Viewed 2327 times

Heater pad wiring:

014 Wiring for the Seat Heaters.JPG (3.84 MiB) Viewed 2327 times

015 Wiring for Seat Heaters.JPG (4 MiB) Viewed 2327 times

016 Closeup of the Base of Seat.JPG (3.32 MiB) Viewed 2327 times

Door cards done (I had purchased the door card inserts from MR2 Heaven and that became the base template and Ross then used the backing off the MR2 Heaven insert with the new material & backing then installed it to the door card):

017 Finished Door Cards.JPG (3.92 MiB) Viewed 2327 times

018 Finished Door Cards.JPG (4.33 MiB) Viewed 2327 times

Seats & Door Cards together:

019 Finished Door Card & Seat.JPG (3.8 MiB) Viewed 2327 times

020 Finished Door Cards & Seats.JPG (4.09 MiB) Viewed 2327 times

M+H Seat rails (has the seatbelt buckle mounting point so no need to make one up). Only problem is that these are too low, have to make an adapter plate to suit as the Recaros are sitting on the floor when in them to the rails):

021 SW20 MR2 M&H Low Rise Rail.JPG (2.04 MiB) Viewed 2327 times

022 SW20 MR2 M&H Low Rise Rail.JPG (2.69 MiB) Viewed 2327 times

023 Seat Rail.JPG (2.94 MiB) Viewed 2327 times

024 Seat Rail.JPG (3.81 MiB) Viewed 2327 times

025 Seat Rail Fittings.JPG (1.98 MiB) Viewed 2327 times

026 Seat Rail.JPG (2.21 MiB) Viewed 2327 times

027 Seat Rail.JPG (2.59 MiB) Viewed 2327 times

028 Seat Rail.JPG (2.59 MiB) Viewed 2327 times

029 Seat Rail Test Fit.JPG (2.46 MiB) Viewed 2327 times

[Benckj]

Nice. Good to see some others are still doing a little work & mods to their 2.

[lasersooby]

Thanks Jim. The shell is no longer a shell. It has taken a bit of time but it is now looking more like a car. I will upload a few more sets of images as I get time.

[lasersooby]

Once again, Rockauto came to the party with delivery of a new high amp alternator and a starter motor. Their prices are just so hard to beat even with the shipping included. Recommend people check them out when you are searching for parts:

001 Rockauto Deliveries.JPG (3.92 MiB) Viewed 2314 times

002 Sadly 1 Box was Damaged, but item survived the drop.JPG (2.75 MiB) Viewed 2314 times

003 Alternator.JPG (2.3 MiB) Viewed 2314 times

004 Alternator.JPG (2.38 MiB) Viewed 2314 times

005 Starter Motor.JPG (2.54 MiB) Viewed 2314 times

006 Starter Motor.JPG (2.9 MiB) Viewed 2314 times

[lasersooby]

Visited Rocket Industries in Sydney last November and picked up some Aeroflow items including a TurboSmart FPR. Pricing was pretty good and they had everything that I wanted to setup the w2a intercooler system for the supercharger as well as the methanol tank system for the additional fuel. Here is the catalogue & prices for the items:

001 Rocket Performance Catalogue (Sydney).JPG (4.39 MiB) Viewed 2290 times

002 List of Items Purchased for the Cooling & Fuel Systems.JPG (4.17 MiB) Viewed 2290 times

The stash:

003 Aeroflow Fittings.JPG (3.78 MiB) Viewed 2290 times

Fittings for the methanol fuel system and the water to air intercooler setup:

004 -8AN 180 AF516-08BLK Full Flow Push Lock.JPG (1.96 MiB) Viewed 2290 times

005 -8AN 180 AF516-08BLK Full Flow Push Lock.JPG (1.68 MiB) Viewed 2290 times

006 -8AN 90 AF513-08BLK Full Flow Push Lock.JPG (3.29 MiB) Viewed 2290 times

007 -8AN 90 AF513-08BLK Full Flow Push Lock.JPG (2.69 MiB) Viewed 2290 times

008 -8AN 45 AF512-80BLK Full Flow Push Lock.JPG (2.22 MiB) Viewed 2290 times

009 -6AN Male Flare Union.JPG (1.24 MiB) Viewed 2290 times

010 -6AN Male Flare Union.JPG (1.1 MiB) Viewed 2290 times

011 -8AN AF920-08BLK Orb to -8AN Straight.JPG (2 MiB) Viewed 2290 times

012 AF752-08BLK 0.5inch BSP to -8AN Washer Seal.JPG (2.02 MiB) Viewed 2290 times

013 -12AN AF140-12BLK Straight Female to Male -12AN.JPG (2.28 MiB) Viewed 2290 times

014 -12AN 90 AF513-12BLK Full Flow Push Lock.JPG (2.04 MiB) Viewed 2290 times

015 -12AN 45 AF512-12BLK Full Flow Push Lock.JPG (2.44 MiB) Viewed 2290 times

016 AF172-04 0.5inch BSPP Alloy Crush Washer.JPG (1.96 MiB) Viewed 2290 times

017 AF172-04 0.5inch BSPP Alloy Crush Washer.JPG (1.35 MiB) Viewed 2290 times

Picked up the TurboSmart Fuel Pressure Regulator for the methanol system:

018 TS-0401-1106 TurboSmart FPR2000 Fuel Pressure Regulator.JPG (2.94 MiB) Viewed 2290 times

019 TS-0401-1106 TurboSmart FPR2000 Fuel Pressure Regulator.JPG (1.7 MiB) Viewed 2290 times

020 TS-0401-1106 TurboSmart FPR2000 Fuel Pressure Regulator.JPG (3.58 MiB) Viewed 2290 times

021 TS-0401-1106 TurboSmart FPR2000 Fuel Pressure Regulator.JPG (2.23 MiB) Viewed 2290 times

022 TS-0401-1106 TurboSmart FPR2000 Fuel Pressure Regulator.JPG (1.91 MiB) Viewed 2290 times

023 TS-0401-1106 TurboSmart FPR2000 Fuel Pressure Regulator.JPG (2.1 MiB) Viewed 2290 times

024 TS-0401-1106 TurboSmart FPR2000 Fuel Pressure Regulator.JPG (2.08 MiB) Viewed 2290 times

Aeroflow 340lph E85 Compatible Fuel Pump for the methanol system:

025 AF49-1041 340lph E85 Hi Flow Fuel Pump.JPG (2.66 MiB) Viewed 2290 times

026 AF49-1041 340lph E85 Hi Flow Fuel Pump.JPG (1.77 MiB) Viewed 2290 times

027 AF49-1041 340lph E85 Hi Flow Fuel Pump.JPG (2.21 MiB) Viewed 2290 times

Aeroflow weld on nozzles. These will be welded on the headers at each exhaust port so that we can monitor the exhaust temperature. The sensors will be bolted to each of these nozzles (running a sensor for each exhaust outlet):

028 AF994-01 Weld On Nozzle Fittings.JPG (1.84 MiB) Viewed 2290 times

029 AF449-01 Weld On Nozzle Fittings.JPG (2.82 MiB) Viewed 2290 times

030 AF449-01 Weld On Nozzle Fittings.JPG (1.37 MiB) Viewed 2290 times

031 AF449-01 Weld On Nozzle Fittings.JPG (3.62 MiB) Viewed 2290 times

[tomnomnom]

Just a heads up mate, they will not accept seatbelt mounts on the rail anymore unless they are oem
So for cert purposes, the seatbelt clip will have to be mounted to the floor or tunnel

[lasersooby]

Just a heads up mate, they will not accept seatbelt mounts on the rail anymore unless they are oem
So for cert purposes, the seatbelt clip will have to be mounted to the floor or tunnel

Thanks for the heads up on that mate, appreciate it. Looks like we will have to look for another plan then.