The Superboxer, a new heart for the Silver Bullet

[silverbullet]

If its hardwood I would like 100 sq.m of chequer parquet please!

[silverbullet]

Bypass valve arrived, so had a little tinker after hours.
In a word, its getting close and still looks possible to get it all under the engine hatch, but there will be more casualties: the lifting eyes on the crankcase will have to go, or certainly the front one. I need to drop the compressor just a bit more (20 - 25mm) to get it all lining up nicely:

[silverbullet]

The bypass will need a little bolt-on elbow housing made to mount it on the back of the inlet plenum. I also have concerns about ferocious power delivery and general driveability when using a DJ single plate throttle, so I rummaged in the 7A spares and pulled out this puppy:

Once the chargecooler lower plenums are re-made to suit 2 cylinders per side there should be space to put an extension on the compressor inlet and get it mounted up ok (ignore the cruddy old blower discharge plenum, thats for the ally scrap bin)

This is the spigot for the DJ throttle body:

Likely position for the twin throttle, with a plenum extension running under the RH cooler:

[silverbullet]

Spark plug accessability isn't looking like its going to be a problem, so going coil-on-plug is definitely on the cards
The air filter housing location isn't going to need much of a radical rework either, so the stock air intake can stay in the offside D post.
This means that I will source a standard Jaguar chargecooler "radiator" and mount it up front in the time-honoured fashion.
Thankyou Duncan for helping with the basic calcs; that has really helped me work through the options and now I know that the chargecooling system has (in principle at least) got the heat rejection capacity that this engine will need.
Its going to be a well-stuffed engine bay though!

[silverbullet]

"Will the indignity never end?"

or

"Making good use of an otherwise ruined crankcase"



Explaination: establishing a datum plane parallel to both the crankshaft centreline and the piston bores; referenced to an existing boss on the case (in this instance, the aircon mounting) in order to design the compressor mountings and get it all square and symmetrical.

I will bolt a sacrificial flat plate down onto the machined bosses, then work outwards from the centreline to build up the intake system as a whole.

[silverbullet]

I am starting to think that I might make the compressor mounting in steel and with a baseplate between it and the crankcase (a bit like the original but rather better executed)
At least that will give some protection to the blower if the engine throws a rod...
I can build another engine, but trying to find another Opcon could mean curtains for the whole thing.

[silverbullet]

Slight aside... yesterday was an interesting one.
Some useful info for later on
https://www.google.co.uk/url?sa=t&sourc ... ugBOGALrOQ" onclick="window.open(this.href);return false;

[silverbullet]

Swapped everything into the modded "datum" case and topped it off with a bit of scrap 12mm Lexan that was knocking about. Not showing off with the choice of material, it just makes it easy to find the top case bosses for clearance slots in the final compressor mounting. Now I have a level and square platform from which to work and measure.


Got the hacksaw out:


Nice and snug round the back with that little notch:

That plumbing fitting has to go!

[what2do]

I saw that MI - compression fitting and wondered if this whole project was some elaborate workshop heater that you were getting carried away with....

[silverbullet]

A relic from another time! Classic 80's corner cutting...

Hot news is that I have secured a transmission that can handle the torque without throwing its toys out of the pram

[silverbullet]

Now we are getting somewhere:





The ratios make for interesting reading... ex-R25 V6 turbo!

[max and caddy]

What's this bypass valve all about?

[silverbullet]

It allows the compressor to "idle" when off boost (at small throttle openings, hugh vacuum) so it doesnt put any appreciable load on the engine when cruising.

[max and caddy]

Indeed...so why not use the g60 part as it would suit perfect!

Google... G60 drosselklappe...

[silverbullet]

Got all the Shaguar bits and they work together, pipes line up so no point throwing an odd bit of G-lader in there.
Its working out ok but shortening the compressor nose is proving "interesting" because it has a cush drive and a spring-loaded bearing in there. Bugger knows why and I cant get it apart without making another special tool...