Supercharged 2GR SW20 Project

[lasersooby]

Wilwood Big Brake Kit from MR2 Heaven, includes the mechanical handbrake setup as well:

[Swampy]

Those wilwoods look mint Mo, I'm sure the car will pass the brake test easily when it comes to cert time!

[lasersooby]

I really hope so mate. I am waiting on getting the engine sorted, w2a assembled, supercharger sorted etc so a bit to do before we get to mounting this kit up. Phill's done an incredible job on the wiring so hopefully things will slot in nicely

Those wilwoods look mint Mo, I'm sure the car will pass the brake test easily when it comes to cert time!

[GDII]

Those wilwoods look mint Mo, I'm sure the car will pass the brake test easily when it comes to cert time!

Possible. It has come to light that the handbrake caliper bracket mounting points are possibly not suitable for NZ certs. We will see how that goes.

I really hope so mate. I am waiting on getting the engine sorted, w2a assembled, supercharger sorted etc so a bit to do before we get to mounting this kit up. Phill's done an incredible job on the wiring so hopefully things will slot in nicely

Wiring is mostly done. Just working on the final bits now that I have all the parts.

[Swampy]

How much power are you going for? It's gonna be awesome

[lasersooby]

Hi mate, power hmm. Several things at play here.

I want as much as I can without getting too crazy. With everything we're doing with the engine build, the w2a intercooler setup and fully rebuilt supercharger with the smaller pulley to increase boost slightly, maybe 350 to 400.

I don't have a target in mind, just want as much as we can but running safe. I don't want us to be living or running the engine right of the edge of extreme.

Phill's work around the wiring to run the TRD ECU then wellsetup a Unichip tune to smooth everything out should give us good outcomes and heaps of torque.

Hoping the clutch kit (to be determined) with EA60 6speed will hold everything that we throw at it.

All a bit of a guess mate, will upload the donor tune chart once its done

[lasersooby]

I am sure everyone knows that the TRD supercharger on the 2GR engines have an issue with heat soak from the engine which reduces the efficiency of the supercharger. There are not that many options out there for an intercooler for this application.

Based on this, I started a search for a company that has developed plate intercoolers for superchargers and I managed to find a company based in Melbourne Australia called Elate Manufacturing. I contact them and spoke to the owner of the business, Travis Peek. This is the website details for Elate Manufacturing:

https://elatemfg.com/

Travis' company already produce plate intercoolers for the V6 supercharged Holden engines and this gave me comfort that they could help me with my requirements. Travis has been incredible. He listened to what I wanted to do and asked me to send the lower intake manifold off to him to scan and possibly then work on finding a solution.

The good news is that he has done the hard work by scanning the lower intake manifold then 3D print the intercooler housing for me to trial on the engine.

I received the item this week and here are some pictures of the work that Travis has done so far. I will upload more details on the intercooler setup once we get further into this setup.

Please note that the final versions will be available through Travis' business

Special delivery of the packed item:

Lower Intake manifold that I sent through to Travis and the plate intercooler housing:

3D printed plate intercooler housing:

Intercooler housing sitting on top of the lower intake manifold:

[lasersooby]

Has been a while since I updated this thread.

The supercharger rebuild has been completed by the good Team at Llama Engineering, Alicetown, Wellington. Marc is the man to contact for your needs. They do full engine rebuilds, race cars and dyno tuning as well.

Zachary at Kohl's applied to cerakote color on the charger.

Delivery/pickup of the package

Christmas came early:

Marc machined the snout of the supercharger to fit the smaller pulley for increased boost:

Bullet Performance in Brisbane supplied the smaller pulley, bearing kits and the oil for the supercharger:

Parts that were removed from the charger, sorry no pictures of the needle bearings that are located at the back of the housing as they got pretty munted when they were removed. Parc had to buy another bearing puller and make a contraption to remove the bearings as he broke the first bearing puller:

Bypass valve (my bad on the description ):

Under side of the supercharger:

[thegreatestben]

That red is a thing of beauty. Enjoying the progress!

[lasersooby]

Hey mate, been a while. Hope all is going well in your neck of the woods.

It's coming along slowly but nicely, will upload a few pictures tomorrow once I've sorted them out.

Getting pretty exciting.

Chat soon, regards

[lasersooby]

Both heads have had the porting and polishing work completed by Francois, Elite Automotive, Pirani Place Palmerston North. He has spent hours and hours on getting the flow right. Volumes for each of the ports is within a ml of each other:

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[lasersooby]

More pictures of the head work:

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[lasersooby]

Just a few more images of the head:

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Lower Intake Manifold Ported & Polished:

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[lasersooby]

Hi all, Elate Manufacturing - Geelong, Victoria, Australia have just about finished my plate intercooler for the engine. Check out the link below:

https://m.facebook.com/story.php?story_ ... 0051045951

Looking forward to getting my hands on this

[lasersooby]

Had installed the Wilhelm Raceworks Suspension Geometry Kit in the front and after a few discussions with the Engineer, a call was made to change the nyloc nuts (top & bottom) to castellated nuts with cotter pins to hold all the pieces together. This is what the tapered rod stud looks like that comes in the kit:

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The tapered rod stud uses 7/16" nut at the top and 5/8" nut at the bottom (kit made in the US hence the imperial sizes). I purchased the corresponding castellated nuts and pins from Steelmasters - Tremain Avenue, Palmerston North and got busy with getting the mods done.

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Basically, I put the parts back together on the car and torqued them up to the correct spec of 30ft.lb then marked the place to drill the holes on the tapered rod stud:

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Once the holes were done, go the pieces back together and job completed, lot happier that this will pass compliance:

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