Project Yeti! Or Blown Mazda

[Rogreborn]

I dunno if its because its 2am on a Friday, but i just have a feeling i need to do something to my car for next summer. I have come to the conclusion that i must supercharge the thing. I have chosen this route for forced induction because i think its easier and less invasive than a scratch turbo setup. Might even be cheaper but we shall see.

So im currently in Phase 1 of this project, acquire the parts.

First part on my hit list is the the biggest one, the supercharger himself. I think ill go with the roots style, more specifically an eaton M45 or M62. I have chosen this one because its the easiest to obtain and easiest to repair. Also, their the most abundant on kijiji. I hope to hear back, at a more sensible hour, about one today. Once said blower is in my possession i will have to make a custom outlet and inlet manifold to fit 2.5" hose's.

Second part to obtain will be a front mount intercooler that fits on my little sedan.
Next will be hoses and pipe.
Then the last part will be to upgrade my fuel injectors and possibly fuel pump (hoping i won't have to upgrade that).

The big step after all that is actually making up a mounting bracket and tensioner setup for the custom build. Since my car does not have AC, I am fortunate to have easy access to my crank pulley and only need a separate belt to drive the supercharger. I have measured out the back of engine and there is a ton of room to fit this thing in.

After all that it will be tuning the beast ( which i have no experience in at all).

I've done some research on how to do this little setup and actually had a supercharger installed on my old Focus, however i did not do the install i just drove the crap out of it.

I'll probably be looking to the community for some help in either acquiring the necessary parts or even with installation/fabrication. Any and all help is appreciated.

[Cab0oze]

Sounds like a fun project, look forward to seeing pictures of the install :)

[staax]

Good luck! Subbed to this thread!

[Hyperion]

Good luck.
Hks injectors are $800+
Siemens Deka 60lb injectors however are $160
If you want, there are often cx racing fmic's that work well for 10> lb of boost and often pop up on the Facebook mazdaspeed buy/sell group for $300ish. Otherwise, there's a good fmic set up for sale on tm3 right now.

[jay93]

Wow, super charger in a mazda 3 this is new to me. Good luck

[Fack_Dude]

Subed for another "zoom zoom boom" build.

[Rogreborn]

I hope for no boom. With the pulley on a standard Cobalt Sss is 85mm and our crank pulley is 133. I calc about 8.5 Psi then there will loss threw the intercooler so probably 6-7 threw the intake manifold.

[Rogreborn]

Im hoping next week to get the exhaust all setup MSDS headers and Racing beat exhaust to handle the added boost.

[zoomzoomtech]

Is this a street car daily driver? Power expectations/goals? Is it a manual trans...

[Rogreborn]

Going to continue driving it daily. Power goal would be 200+ hp and torque. I know 1.8L miata with this setup with a M45 supercharger and they reach 190's. Of course its manual, ill drive it till clutch goes and then upgrade to a better clutch later.

[greyseason]

You seem to have this planned out, if you need a extra set of hands id be down to turn a wrench!

[Rogreborn]

The most difficult part will be fabricating the mounting brscket for the blower and tensioner pulley. It has to be just right or ill be eating belts like candy. The only downside is i have very limited fab/welding skill, so that part could get pricey. Anyone know a really good metal/fab shop in tricity area?

[Dave_The_BMXER]

Wow, super charger in a mazda 3 this is new to me. Good luck

I feel like there was another in the US some place.

[taz4432]

I feel like there was another in the US some place.

There was a kit made but the company went under before it really ever got released to the masses. It was made by F2 and had gained quite a bit of interest and put down some decent numbers but I think only a few kits of their 'Stage 1' setup ever got out in the wild.

This all went down probably 4 years ago or so.

[Dave_The_BMXER]

That all sounds about right... didn't realize it was so long ago.

[Rogreborn]

Here is a little update of what has been done so far.

Got the blower G-Lader off a G60 Corrado.
http://i954.photobucket.com/albums/ae24/RogReborn/Mobile%20Uploads/20141129_130249.jpg (http://s954.photobucket.com/user/RogReborn/media/Mobile%20Uploads/20141129_130249.jpg.html)
MSDS headers on.
http://i954.photobucket.com/albums/ae24/RogReborn/Mobile%20Uploads/20141124_162009.jpg (http://s954.photobucket.com/user/RogReborn/media/Mobile%20Uploads/20141124_162009.jpg.html)

Racing beat exhaust installed.
http://i954.photobucket.com/albums/ae24/RogReborn/Mobile%20Uploads/20141124_161928.jpg (http://s954.photobucket.com/user/RogReborn/media/Mobile%20Uploads/20141124_161928.jpg.html)


More to follow. Looking for a FMIC and bypass valve.

[ottoyu34]

Nice, what specific model is this? gen2 hatch?

[Rogreborn]

Gen 2 Sedan 2.0L.

[Noisy Crow]

The mazda supercharger project isn't dead.... it just seems to be going really, really, slow:

http://www.moccforums.com/forums/index.php?PHPSESSID=ae4fbfdd1cd0daf81cf1fe2dbccaed 6d&topic=32015.0

Maybe they would be willing to sell you a supercharger mount, or at least share the design.

[Rogreborn]

Picked up some more goodies.

http://i954.photobucket.com/albums/ae24/RogReborn/Mobile%20Uploads/20141203_074207.jpg

http://i954.photobucket.com/albums/ae24/RogReborn/Mobile%20Uploads/20141203_074309.jpg

http://i954.photobucket.com/albums/ae24/RogReborn/Mobile%20Uploads/20141203_074052.jpg

[SweetnessGT]

Good luck bro - let me know if you need any help setting it up. I'll miss the project but it's good to see somebody else has the supercharger and will do what I intended with it.

Just so you know the sending line banjo fitting is 1/8" NPT, so you may need a 1/4" - 1/8" adapter to hook it up to your oil source. The Supercharger requires about 7 psi of pressure and that tiny thin line restricts it quite well to that level.

I was going to make everything out of 1/4" plate steel (which I'd acquired)... bunjee the supercharger to the engine in-place and make brackets out of cardboard... then transfer to 1/4" MDF. You can then bolt up the charger to the plates and focus on lining it up with a belt. Depending on your belt routing you can get away with an extra idler pulley and the stock tensioner. If you need a list of the bolt sizes I can get you that.

Your two biggest concerns will be lining up the belt and the oil return to the pan. After that the project is cake. I had this project almost complete for my car with just a digital caiper, drill press and high-end jigsaw with steel-cutting blades - you can get it done without issue. A laser level to line up the pulley will help - once you work out the spacers with washers measure it with a digital caliper and cut your spacers from aluminum tube. I got all my metal from The Metal Supermarket in Mississauga.

I'll be around and checking in on this.

[Rogreborn]

Hey guys little update.

I'm looking at upgrading my fuel injectors. But, i need some help dunno what i should get. I dunno what type or fuel rating i should be looking for. Any ideas? I want something economical not super expensive cheaper the better. Throw out names, price and fuel rating with each suggestion.

[Canadianbacon]

91 at costco is always pretty cheap i usually go there(10-12cents cheaper from Shell,Esso and big stations, IMO 94 Petro-Canada expensive.
Esso has 93 now came out this year, not sure on price

[greyseason]

Hey guys little update.

I'm looking at upgrading my fuel injectors. But, i need some help dunno what i should get. I dunno what type or fuel rating i should be looking for. Any ideas? I want something economical not super expensive cheaper the better. Throw out names, price and fuel rating with each suggestion.
I want this to work for you, I really do but it's these types of questions that make people shake their head.

How much psi are you looking at? Compare that to turbo setups people have and go from there.

[greyseason]

Different fuel requirements come from a tune.

I'd say 1000cc injectors with 87 and you'd be good

[Rogreborn]

1000 cc i believe is high. I was thinking of 600 cc Deka Fuel injectors. They are cheap and would easily be able to handle the power im looking at achieving.


I want this to work for you, I really do but it's these types of questions that make people shake their head.

How much psi are you looking at? Compare that to turbo setups people have and go from there.

It doesn't hurt to ask questions. I already think i know the path im going to go but i like to hear what other peoples thoughts are. If they know of a Fuel injector i don't. Ill be running 91 Octane and tuned for it. I think ill just go with Deka 600cc they are probably the best bang for buck.

[Aitch]

Different fuel requirements come from a tune.

I'd say 1000cc injectors with 87 and you'd be good
1000cc is overboard for a mild forced induction build. I also question the logic of tuning a FI engine on 87 octane.

[Rogreborn]

1000cc is overboard for a mild forced induction build. I also question the logic of tuning a FI engine on 87 octane.

Agreed. This car will be tuned for 91 octane and probably 600 cc injectors. I was thinking of maybe going 440 or 480 but do not know a brand to go with.

Also here is some of the PSI info for my particular blower and crank pulley setup, if anyone is interested.

STOCK Mazda CRANK + 78mm G LADER

RPM Crank Pulley SC Pulley G Lader RPM PSI

1000 5.2362 3.07 1705.602606 1

1500 5.2362 3.07 2558.403909 2

2000 5.2362 3.07 3411.205212 3.5

2500 5.2362 3.07 4264.006515 4

3000 5.2362 3.07 5116.807818 5

3500 5.2362 3.07 5969.609121 5.5

4000 5.2362 3.07 6822.410423 6.5

4500 5.2362 3.07 7675.211726 7

5000 5.2362 3.07 8528.013029 8

5500 5.2362 3.07 9380.814332 9

6000 5.2362 3.07 10233.61564 10

6500 5.2362 3.07 11086.41694 11

7000 5.2362 3.07 11939.21824 11.5

[Kiyomi]

looks nice and progressive. just wondering, does that mean your going to be in boost all the time, even when cruising/idle?

[Rogreborn]

looks nice and progressive. just wondering, does that mean your going to be in boost all the time, even when cruising/idle?

With this particular supercharger its positive displacement so yes ill always be in boost. But 1 psi of boost is much like sucking in air normally for a car. It's once i get to 3+ PSI where ill actually notice it.

[Kiyomi]

With this particular supercharger its positive displacement so yes ill always be in boost. But 1 psi of boost is much like sucking in air normally for a car. It's once i get to 3+ PSI where ill actually notice it.

interesting. curious about how your fuel mileage is gonna be affected if your always in boost, even if its low boost. whats your tuning solution gonna be?

[Rogreborn]

interesting. curious about how your fuel mileage is gonna be affected if your always in boost, even if its low boost. whats your tuning solution gonna be?

I'm going with Mat at OVtuned.com he will be doing my tuning and probably have to play with the idle a bit. I have a recirculating valve on the pressure side for shifts and whenever im in boost and the throttle body closes. Ill leaving tuning to Mat, but he thinks it should not be too bad since the supercharger and boost is very predictable.

Gas mileage may suffer, but this is not a fuel economy build, if it was i would not be supercharging.

[Kiyomi]

I'm going with Mat at OVtuned.com he will be doing my tuning and probably have to play with the idle a bit. I have a recirculating valve on the pressure side for shifts and whenever im in boost and the throttle body closes. Ill leaving tuning to Mat, but he thinks it should not be too bad since the supercharger and boost is very predictable.

Gas mileage may suffer, but this is not a fuel economy build, if it was i would not be supercharging.

good to hear u got a plan and also that your not building it for fuel econo :D. really curious to see how it turns out and best of luck. you gonna be getting the software that you can change yourself, or your just gonna leave it to ov? imo, its nice to have the software so you can see whats going on, and start to learn about tuning.

[Rogreborn]

good to hear u got a plan and also that your not building it for fuel econo :D. really curious to see how it turns out and best of luck. you gonna be getting the software that you can change yourself, or your just gonna leave it to ov? imo, its nice to have the software so you can see whats going on, and start to learn about tuning.

I already got the Tactrix and bought my license last night. Ill leave the tuning to OV, however ill have the software so i can see what is going on and learn a bit about it.

[Kiyomi]

I already got the Tactrix and bought my license last night. Ill leave the tuning to OV, however ill have the software so i can see what is going on and learn a bit about it.

if you have any questions about the software, ill try and help if mat is too busy or he doesnt explain to customers anymore how it works.

i was also thinking of holding a local get together to discuss and share ideas and talk about the mazdaedit software, its capabilities, and tuning theories for the n/a owners that would like to try tuning their own vehicle or would like to learn more about how things work.

[Rogreborn]

if you have any questions about the software, ill try and help if mat is too busy or he doesnt explain to customers anymore how it works.

Cool that be awesome. He has been very busy lately, but i heard he has hired someone to help him with getting tune's out quicker. But it is always nice to have someone close to home who could help me if i have any questions.

[Kiewan]

Subbed because this is pretty interesting. Best of luck.

[Canadianbacon]

Matt took over a month to respond to my email and update my new tune with my log

[Girds]

Matt took over a month to respond to my email and update my new tune with my log

If you read facebook Matt is apparently taking time off and try messaging Benjamin instead

[Rogreborn]

Project update.

I have 60lbs Deka injectors courtesy of Mat at OVtuned. I have a base boost tune from him as well; he was very quick to get it to me btw. Then i ran into kinda of a snag.

I have been able, so far, to keep this project very cost effective. Until i got an estimate on how much it would cost to get some custom mounting brackets made up. Also, having issues on locating a decent tensioner assembly and idler pulley to work. With my wife on mat leave and our little man in the picture, money is kind of tight, so i think ill be putting this project on ice for the time being. If only money grew on trees.

The Yeti is not dead, just in hibernation.

I guess ill just have to drive my buddies new Focus ST to feel the boost.

[SweetnessGT]

Hey man, got your email.

First off - sorry to see you have to shelve the project. I will tell you that I was going to cut my own bracket out of metal - like I said earlier fab it up with 1/4" MDF. Then transfer this to 1/4" plate steel and cut it yourself with a high quality jigsaw and metal blade. A drill press will drill the holes no issue. I bought a big enough 1/4" plate of steel from The Metal Supermarket in Missisauga to make 3 brackets for all of $45. Frankly you should be able to make the bracket yourself but you have to get your MDF bracket PERFECT. It will take re-making the MDF bracket about 3 times to get it 100% but MDF is a joke to cut and drill so it's really a matter of labour/precision over cost/difficulty.

I also used a laser level on a tripod to ensure the charger was lined up 100% to the rest of the belts. Like I mentioned buy a bulk box of washers to shim it side to side and once you have it perfect buy some aluminum dowel from The Metal Supermarket and cut it to exact length. This is easy to do with a metal chop saw and some care.

Lastly regarding the tensioner - can you post up a picture of your proposed belt setup? Here was how I did things:


Initial fitment using bungee cords so I could rough up a bracket out of cardboard:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Bungee%20Cord%20Fitment%20and%20Bolt%20Positions/IMG00624-20111127-1616.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Bungee%20Cord%20Fitment%20and%20Bolt%20Positions/IMG00624-20111127-1616.jpg.html)


Cardboard template mocked up for a rough shape for the MDF Bracket:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Cardboard%20Template1/IMG-20120626-00025.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Cardboard%20Template1/IMG-20120626-00025.jpg.html)


Transferring from cardboard to MDF:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00027.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00027.jpg.html)


http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00028.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00028.jpg.html)


Added bolt locations for G-Lader:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00030.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00030.jpg.html)


Added bolt holes to secure G-lader via brackets to the block mounting locations:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00035.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00035.jpg.html)


Shimming supercharger on bracket with laser level - the pulley/ribs line up perfect to the stock system:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00037.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%201/IMG-20120630-00037.jpg.html)


Secondary bracket created for other side of charger - this required a dual bracket and spacer. Technical issue was to work around the stock oil filter:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00042.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00042.jpg.html)

http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00055.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00055.jpg.html)


http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00050.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00050.jpg.html)



So here's the question you're asking about - belt routing. A supercharger requires 270 degrees of belt wrap to avoid it slipping on the pulley and costing you boost. Here is where I stood once the supercharger was bolted up and lined up vs the stock system... I decided to add an IDLER PULLEY at about 8 o clock from the supercharger pulley - right next to my thumb is the stock tensioner:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00057.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Wood%20Bracket%202/IMG-20120702-00057.jpg.html)


I went online and found the perfect size one with no ribs for $12 on ebay - came with the bearing and everything. This is a floating pulley that you shim out from the bracket and simply bolt down - you can put it anywhere that it may work on your bracket:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Pulley%20Roughed%20In/IMG-20120712-00062.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Pulley%20Roughed%20In/IMG-20120712-00062.jpg.html)


Ideally to get a better belt wrap the idler had to be up another inch or so but due to the belt system I wasn't going to be able to do that. As you can see there's 1/2" between the new idler pulley and the stock tensioner. You need to find a way to utilize the stock one - you cannot have two tensioners on the same system. The other suggestion is to slot your mounting plate with that idler pulley and move and tighten it yourself which a lot of V8 chev guys do with roots blowers on a 350.


As you can see it was all perfectly lined up:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Pulley%20Roughed%20In/IMG-20120712-00064.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Pulley%20Roughed%20In/IMG-20120712-00064.jpg.html)


Oil lines run:
http://img.photobucket.com/albums/v720/remus2k/G-Lader%20Supercharger%20Build/Oil%20Lines%20Installed/Toronto-20120713-00074.jpg (http://smg.photobucket.com/user/remus2k/media/G-Lader%20Supercharger%20Build/Oil%20Lines%20Installed/Toronto-20120713-00074.jpg.html)


Stock G-lader sending line and a 1/4" brake line to a fitting as high as possible in the oil pan. I was fortunate to have the charger above the oil pan so a gravity drain was possible - remember the G-lader runs on all of 7 psi of oil... that stock line restricts it heavily so it's a mere trickle to the oil pan unlike a turbo setup.


Let me know if you have any further questions - hopefully this helps you. You can DEFINITELY make the bracket yourself in your garage - just head to The Metal Supermarket for the materials and get a good jigsaw or bandsaw with a metal blade and cut slowly with cutting oil. Ditto using the drill press. All the work I'm showing you took about 20 hours total to do and I was BRAND NEW to fabrication. The only welding I was going to have to do were the metal L-brackets to bolt the mounting plates to the engine block and after 2 hours of practice I was 100% ready to accomplish that too.

Really since you have the charger it should cost you no more than $100 in materials to get it mounted up and lined up and ready to go - the rest of the expense is the intercooler/piping/silicone couplers/t-bolt clamps/bov/tuning. No need to get an expensive plate machine-cut... if people can make brackets at home for alternators for their V8's surely us 4cyl guys can make a slightly more complicated bracket for a supercharger. ;)

Good luck!

-Chris-

[r4BBiT]

I have 60lbs Deka injectors courtesy of Mat at OVtuned. I have a base boost tune from him as well; he was very quick to get it to me btw. Then i ran into kinda of a snag.

From what I read on mazdaspeed forum all you need is really 330cc+ so, 440cc probably would of been fine, but you already got them.


if you have any questions about the software, ill try and help if mat is too busy or he doesnt explain to customers anymore how it works..

Just so you know with our Personal licenses we don't really have access some of the features that Mat does with Pro version. Some of those features are critical to make non-FI ECU work good with FI; you need increase resolution of load tables as non FI end 1.0 and have a lot less columns.

What makes it worse is that epifan "encrypts" the ROM file as he reads it so looking at it with normal HEX editor is not an option.