FTO AUSTRALIA

I have been test fitting this afternoon, all looking good.
Just need the intake air tank of the charge cooler fabricating now to join it to the blue outlet on the side of the supercharger (will have a 45degree 76mm hose on too), will take the car and parts down to the fabricators early next week for this last bit.






(with bypass valve in place)

Sooo awesome. Cool to see all the bits finding their place.

sh*t yeah!

Please tell me you are not going to use the factory air intake pipes
I would say the answer is no
But dam it's all looking great.

aza013 wrote:Please tell me you are not going to use the factory air intake pipes
I would say the answer is no
But dam it's all looking great.

No I will be replacing that, i'm a fan of the HKS mushroom filter - 'Super Power Flow'
People can be up and running using the factory pipe and air box without having to think about replacing it yet or they can replace it - up to them, or they may already have an intake that they want to use and they will still be able to if it currently fits on their car.
One of the main aims with the design of the supercharger intake was to put the throttle body where it is from the factory and it is almost in the same spot.

Would look good with my UAS intake..

Been to see the fabricator today about the last bit, the inlet for the charge cooler - car is going in tomorrow

One thing to consider when fitting the supercharger is that the brake reservoir needs moving as it's in the way, so here's a couple of pics of the remote reservoir kit that I've put together.


This won't be included in the Supercharger kit but will be an option if required or standalone if you don't even want a supercharger but like shiny sh*t.

Hose is from HEL Performance, this may not be needed if you don't have ABS (I do so have less room) but I will find out as my sons car doesn't have ABS.
This is to replace my crappy diy job that I fitted a while ago as i'm not happy with it.

Charge cooler is done and I now have all the parts. The inlet to the charge cooler will be getting some CAD loving for future ones and will be 3D printed in Nylon on an EOS SLS machine like the supercharger intake. The reason I didn't do this before was because my cost estimate for this put it more expensive than Aluminium fabrication - I was wrong, it's cost me a future at the fabricators so in future will just get the bits I have to done there (welding flanges to the core, water end tanks and intake runners to flange).

Need to get it fitted.

First job will be the new AEM wideband AFR sensor and gauge which should be a doddle as I already had one in there but loaned it out to Rowan (well he has it now), and steal back my boomslang harness for the emanage from him (another is on the way).
Injectors.
Then on to the actual fitting of the kit.
Will still have the mini rad and pump for the charge cooler to fit too but this can be done in isolation.

Sunday might be the day! (daughters 11th birthday party on Saturday, got to get the priorities right)

Yaaay, almost there! I think what your daughter would want for her birthday is a ride in a supercharged FTO (okay I may be projecting a little)

bjk wrote:Yaaay, almost there! I think what your daughter would want for her birthday is a ride in a supercharged FTO (okay I may be projecting a little)

Yes I think you are and rightly so.

It would also help if I didn't have another FTO on the drive that's in pieces too (Rowans) and he's now using mine for work when I want to do stuff to it! I've told him to buy a bike.

Just make him walk.

Ok been busy with the lads car but had some time this weekend to work on mine.
Spent about 4 hours Saturday and a couple of hours today, most of the time was around the pulley bracket as I had to make a few adjustments - these will be getting carried through to the cad design so I don't hit the issue with the next ones (which I will also test fit before going out).
Put the 275cc injectors in too, the emanage and boomslang plug and play harness.
The belt is on and seems to be aligned ok as it's not trying to walk off.





That tensioner looks familiar...

And noticed I forgot to plug the IAT sensor in on the side of the charge cooler = 3-4mm air hole / ass hole, take your pick

(Stock intake pipe is just for now and highlights that you can use whatever your existing pipe is)

Started it up, very nice supercharger whine but I knew something was wrong as I shouldn't be hearing that yet, big vac leak somewhere causing the revs to go straight to 6K.
Ooops - forgot to put the brake servo pipe on!
Tried again - still a big leak somewhere and i'm suspecting the SC inlet isn't sealing right so pulled it off and turned the rubber internal gasket around as I reckon it will crush on then and seal better, and failing that some sealant to help it out (this is just vac side not boost). Oh and I was missing a clamp off the supercharger outlet too, was rushing.
But I've run out of time this weekend as I need the car tomorrow so had to put it all back to normal
Oh well, will only need an hour or two next time hopefully

Engine bay and engine needs a clean too.

sooo cloooose!

bjk wrote:sooo cloooose!

Yeah pissed me off a bit that I had to remove most of it but no point rushing and ruining something, won't be long now and also won't take long to refit next time.
I can do some testing off-car of the supercharger intake to make sure it's sealing when fitted to the charger.
Removing it also helped me see a better way to fit it all in terms of steps.

Rob Furniss wrote:

bjk wrote:sooo cloooose!

Yeah pissed me off a bit that I had to remove most of it but no point rushing and ruining something, won't be long now and also won't take long to refit next time.
I can do some testing off-car of the supercharger intake to make sure it's sealing when fitted to the charger.
Removing it also helped me see a better way to fit it all in terms of steps.

Yeah, exactly. Practice makes perfect as they say haha.

Oooh, yeah so close!
So possible running this weekend?

Technikhaus wrote:Oooh, yeah so close!
So possible running this weekend?

Oh yeah for sure

EDIT: Managed to seal the supercharger intake / coupling, won't be leaking from there.

Digital thermometer going in to display the boosted air temp inside the charge cooler/plenum just before it enters the intake runners, (after charge cooler has dropped the temp i'm hoping)

Will be adding another one to display the temp after it leaves the supercharger just as it's entering the charge cooler so I can compare how much cooling is going on.
This panel thing is temporary, will get one laser sintered out of Nylon the next time I put an order in for something, I just knocked this up yesterday. I don't use the ashtray so for me it works.


I did have two thermometers but I busted one, ordered a couple more as they are quite cheap.
There are some 52mm dual temp gauges on the market but not quite so cheap and long delivery time (or higher cost to buy already landed ones).
Will be adding a couple of ports to the charge cooler so that anyone who wants to go down this route can add their own gauge/sensors.

Not much to say yet really (that's good).

Boring bit, excuses / explanation: (feel free to skip this till you see some pics and smiley faces later with any luck)
I had another try Saturday and the idle was still way too high (almost 5000rpm) meaning big leak.
Think (hope) I found it though, if i'm right it was due to one of the nuts underneath the cc just catching on the rear rocker cover and stopping it seating properly on the intake manifold. Hell I knew it was going to be close but this nut (rotated with the corner pointing down \/ ) was doing it. I've since rotated the nut slightly (so it's \_/ if that makes sense).

Why nuts? It's a modular charge cooler - bolted together, but my idea of using 6mm bolts and tapped threads had to be changed for three of the holes underneath as they had already been drilled out to 6mm and 6mm bolts going into no thread... hence 3 nuts on to tighten it up.

Also re the clearance of the rocker cover:
I have a Delrin Thermo gasket in place between the charge cooler and intake manifold which is probably 4mm.
Yesterday, to help with clearance I also added the stock metal gasket, not sure what it measures (as I didn't measure it), but I also made another gasket out of 0.8mm gasket paper so i'm probably up from 4mm to 5mm-5.5mm plus the rotated nut sorted, and I tightened the rocker cover bolts a bit as they weren't that tight.
Charge cooler seems to now seat better, will know about the idle when I fire her up at lunch time.

Long term / design solution to this issue? Well for one I won't be having those nuts on, they are only there due to how the charge cooler inlet has been made and the design is changing for the next round (the production ones).

Will also get slightly thicker Delrin intake manifold gaskets made up for the production kits - just 2mm thicker.

Fingers crossed for lunch time, itching to go for it now but I have to work.

Certainly a lot of trial and error with this sort of thing! Keep at it Rob.