For those that followed the topic on the other forum, or are new to it. Due to other car issues, I never had the time to 'beef up' the first prototype before WCBF, and refused to run it without my LSD (which wasn't ready in time) anyway. Things have changed a bit now. The new motor is strong, the car is dialed in very well in it's de-tuned state, and I'm ready to move forward with what I hope will be the FINAL or permanent version, rather than a second prototype.

A little history first:
The Series 1 is a totally different animal to begin with. Raising the Supercharger with a traditional stacked-plate intercooler is impractical for two primary reasons. First, the nosedrive is actually attached to the accessory bracket, requiring expensive customization. Second, there are no inexpensive fuel rail solutions for the Series 1.

The good news is that there's room in the Series 1 LIM for a 'zero lift' intercooler that might have similar thermal capabilities to ZZP's short stack IC, and the Series 1 actually has more usable WIDTH inside than the Series 2 does. Many problems still exist though. A few pics of the first prototype showing the LIM and SC modifications:

























Pic showing the Series 1 manifold (left) and Series 2 manifold (right) and how the widths vary greatly in the plenum:














Cross-section showing how the prototype's inlet and outlet were sealed against vacuum/boost leaks through the LIM wall:




Testing proved it to work very well, but it had some weaknesses in my connections to the inlet and outlet of the inner (LIM) core (heat exchanger). That is essentially the only place that needs improvement in the design, and I'm working on a solution. Keep in mind I had to shorten the chosen heat exchanger to length requirements dictated by the LIM, and I'll improve those 'repair connections' as well this time around.

I'm also considering moving forward sooner than planned on a slushbox, and possible relocation of the front radiator for the intercooler.

FYI, I've already blocked off my EGR to keep the core clean, and need to replace the rotors in my IC-machined supercharger (have replacements already). I may also bypass/block the PCV. It's important to keep the IC core as clean as possible. Periodic use of my water injection (still plumbed into the TB) should help. I MAY add an inspection port to the LIM or SC that I can use later with a borescope to inspect the inner core by simply removing a threaded plug.

I'll keep this updated as I make more progress (current system is on the bench right now).

_________________

Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

Found my container for my slushbox.

Thanks to whichever WCBF'er left this behind.




And I'm not kidding. Perfect size.

_________________

Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

That's intercooler.

And its normally something like a copper coil placed in ice water I would imagine.

If I'm not correct...I'm probably on the wrong subject altogether. But seeing as a drought keg is insulated AFAIK...it would be correct for the application I'm thinking of...with a drain installed of course.

_________________
John
Now: '15 Toyota Prius III | 134 hp 2ZR-FXE | Silver | 36k
Now: '03 Honda CR-V AWD | Slow 4-Cylinder | Dirt | 180k
Then: '07 Ford Fusion SEL | 221hp Gen I VVT Duratec 3.0 V6 | Tungsten Silver | 150k
Then: '99 Toyota Avalon XL | 200hp 1MZ-FE 3.0 V6 | Diamond White | 189k | Sold: July 2015
Then: '11 Ford Fusion SEL | 240hp Gen II VVT Duratec 3.0 V6 | Ingot Silver | 84k | Totaled: Oct 23 '14 (Rear-Ended)
Then: '96 Buick Park Avenue Ultra | 240hp Series II L67 | Medium Dark Lichen | Bought: JAN 11 @ 135k | Accident: FEB 3 '12 | Crushed: MAR 1 '13 @ 153K
Then: '98 Pontiac Bonneville SSE | 205hp Series II 3800 L36 | Topaz Firemist | Bought: NOV '09 @ 74k | Accident: MAY 28 '10 | Crushed: MAR 15 '11 @ 84k
Then: '93 Pontiac Bonneville SE | 170hp Series I 3800 L27 | Dark Yellow Green | Bought: JULY '07 @ 92k | Sold: JULY '12 @ 118k
Then: '89 Pontiac Bonneville LE | 165hp 3800 LN3 | Medium Garnet Red | Bought: JAN '05 @ 117k | Sold: SEP 30 '07 @ 152k

Your welcome Bill.

That really should make a nice intercooler chill box.

_________________

2000 SSEi - SilverBullet - 78,000 kms, 4" "straight shot" custom headlight ram air inlet, TOGs, 1.9's, Lsd, 2.9-3.4"MPS 10-15 psi, Ported GenV, EGR eliminated, OR pushrods, oil volume kit, trani cooler & shift kit, Titanium retainers, 90 lb springs, 160 Stat, 42# injectors, Fuel pump voltage increase, Wideband O2, 3" to dual 2 1/2" Magnaflows, Snow Meth/water injection, after SC temp gauge, 255/50WR17, timing commander set 15-18*@WOT, 2 speed Fan over-ride, disabled DRL, Solid motor mount, Meziere Electric water pump, adjustable fuel pressure regulator, Drilled & slotted rotors/ceramics, GXP sway bars and STB, Upgraded and rebuilt transmission with ZZP 2500 rpm stall TC, Pioneer Bluetooth stereo with sub and 800 W amps, PB 13.5 quarter, (April 2014 car of the month)

Yup. Copper coil enters and exits through the wall, coiled up inside. Fill it with ice, put the lid on. Drain it when it gets full. This is the only way to achieve intercooler temps below ambient, and is typically the last thing in the system before it hits the SC.

Local brewery has a beer tap they rent out with the same type of system. No icing of the key needed.

I'll have to insulate this can. It's single-wall.

_________________

Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

I Like!

what the beer or the idea

_________________


buick regal ls 2002 L36 Buick regal 1983 357 sbc ,2003 Buick park avenue ultra
modkn4750,CAI,er rockers,powerlog,2.5 downpipe,high flow cat,dynomax muffler,hv3,ported LIM,autolite 104,waterpump u/d pulley,180 stat,aeroforce scan gauge,etx mag 17x7.5,245-45-17 flaken ze 912,
pb 14.97@92.77mph 2007 pb 2008 95.45 mph
don

Yes and Yes

I hate Heineken, but I guess technically, it's still beer. And I have to thank them for their contribution to the 'upgrade' part of my project.

One of the big things I wanted to accomplish is to have no mechanical connections (possible leak point) inside the LIM. It doesn't look like I can make that happen, considering the materials I have to work with and the limited space.

It will be far more 'robust' in design this time though. Through simplicity.

_________________

Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

At least it's the right color already, and if you insulate it, the Heineken logo will be covered up and you can do a Zilla Motorsports logo on the outside of the insulation.

_________________
PontiacDad at WCBF `08: "By any chance, was his name. . .Radomir?"

R.I.P. 10/31/15: 1997 SE: "Silver Shadow"
`05 Mercedes S500

Hoping after it's all done, you'll never know it's not an OEM part under there.

Also have some new magic 'stuff' on the way in order to better seal the inner core after shortening it. Should know if it's successful sometime next weekend.

_________________

Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

Ever think of using something other than water to cool this off? For instance, how about hooking it up to a big bottle of CO2 and use the expansion of the gas to cool it off. Better yet, re-route your A/C so that this becomes your evaporator A race car doesn't need A/C, does it?

I said that as a joke but hmmm I wonder if that WOULD work?

Alternately, you could use your A/C system to cool off the water in your slushbox.

_________________

1992 SSEI 170k miles

CO2 comes in a bottle and costs money, and is unsuitable for daily driving.

AC robs horsepower.

A traditional water-air intercooler can run full-time with no extra cost but a few amps to run the pump. Slushbox costs a bag of ice, and is only for the track or very hot trips.

Air-water intercoolers are far more efficient than air-air. I think I'm on the right track.
This version (not the one posted here, it's the prototype.....talking about the 'upgrade') has several improvements and should provide long-term reliability and performance.

While the prototype worked GREAT, it didn't have the durability I needed, and I knew it at the time. I needed something just good enough to prove the efficiency, then go back to the drawing board.

_________________

Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

So... what's happened in twelve years? I am taking on an old Series 1 L67 project. Any LIM and SC results are welcomed.

Cheers!

willwren hasn't posted in 8 years and nobody here is innovating for the series 1. You can consider this thread dead. If you want to start a new one feel free, but I'm going to lock this one up.

_________________
-Andrew-

2004 Bonneville GXP | White Gold Tricoat | custom built supercharged 3800 hot rod | garage queen
2014 Town & Country Limited | Cashmere Pearl | 52k | Family Hauler
2002 Ram 1500 Quad Cab Sport | Black| 230k | Official Bonneville Hauler