www.neons.org

Ok let me start this off by saying a couple of things: first of all this will be an on-going project for quite some time, and I'm sure my design ideas will go through a fair amount of modifications, so if you have some constructive ideas I'd be glad to discuss them.
Secondly, this is my project log, I'm doing this because I got tired of my turbo setup and wanted to do something different just for the experience I'm not in this to make tons of power, I understand that a properly tuned turbo system will ultimately make more power than a supercharger system, let me state this again: "I don't care!" I'm going to have fun with this and that means doing it on my own terms.

Ok with that behind me

The car is my 1996 Neon SOHC MTX base model. It's gone through various different build states, first it was a mild naturally aspirated build with throttle body, UDP, long tube header and a couple other minor things. That was too slow so I put it back to stock expecting to sell it. Then I decided to make it a dedicated drag car and custom built my turbo kit for it. Had that for a couple of years, then my truck got totalled by a minivan mom, so I had to drive the car daily- that got old pretty quick driving a racecar all the time.
So I again put it pretty much all back to stock and now I'm going to do this setup. Hopefully it will be a bit more functional than my last setup.

Here's some pictures to start this thing off.

here's the engine bay when I got the car back in 2002


Here's a couple of build shots when putting the turbo system together




setup at that time consisted of"
t3/t4 turbo .60/.48
TTi log manifold, ceramic coated
walbro 255lph pump
Ford Motorsport 30lb injectors
lorenzo fuel rail
Begi regulator
Spec stage 3 clutch
Phantom grip limited slip diff
Solid motor mounts all around
b&m shifter
solid shifter bushings
autometer boost gauge
riceboy 5" tach
manual boost controller
2.5" exhaust
battery relocated to trunk
fuel pressure gauge
johhny race car 6" intercooler
custom cut and welded intercooler piping
55mm throttle body
ghetto hacked firewall
lots of other things I'm sure I'm forgetting

OK on to the new pics:

Here is the car how it looks now



and the engine bay how it looks now.


Here is where the supercharger will reside, hmm might have to do some moving of things


Here is my spare engine that I'm going to mock everything up on before it goes on the car



here is the key starting point, 6-rib crank pulley that still has a four rib section to run the alternator. the only downside of this pulley is how large it is in diameter, that means that the boost level is going to be higher than I want it to be so I'm going to have to change the stock supercharger pulley from a 3" pulley up to the factory m90 charger pulley size of 3.8" which will also keep it from overrevving, of particular importance because I'm running a hotter cam this time around. Also I'm going to keep the power steering this time So I'm going to try to adapt and additional 3.8" 6-rib pulley to the power steering pump to drive that. I'll fill you guys in on how exactly I'm going to put tension on the belt later, I have a good idea of how I'm going to do it, but I want to get the support bracket built for the supercharger before I delve into that.


Here's the M62 that's going to be the heart of this build


Here's my spare aluminum manifold that I'm going to make into a boxed unit to both increase performance and give me more room.


Here is going to be the approximate location of the supercharger, The discharge outlet will be facing the front of the vehicle, it will dump straight into a rotary v-style intercooler with rear facing outlets, then go straight to the intake.


I'm getting smarter this time around and going with megasquirt management, along with a walbro pump srt regulator and stage 0 injectors
megasquirt


A couple of extras going on.
crane 14 cam


AEM cam gear


Gauge cluster setup


There's a few items I'm sure I'm missing as I'm writing this late. However I'm excited to get this part rolling and I'm definitely going to keep this updated as much as possible.

Let me know with some feedback......

Looks like you have things fairly well sorted! After years of "you've gotta do a supercharger custom - get to it", it's refreshing to see someone actually doing it, well, custom.

nice cant wait to see more.

ditto

Ahhh! Ya beat me to it!
I've got the same one sitting on a shelf here in the shop with the same plan. Are you planning to run a FMIC? Since it's already set with a tube output seems to be that it'd be a snap. That's what I'm planning on doing.

Actually that's the input section, but yes I am planning to run a front mount on this. The outlet side faces directly towards the front of the car.

Could we see some more pics of the super-charger?

Finished pics?

ha, yeah finished pictures would be nice, figure on another 5 months or so

I'll try to get some more pics up of the charger soon.

Oh come on, it looks like you were all ready to go up there!!!

This is gonna be one of the project logs I keep an eye on, I wanna see this thing work.

If/when it does, be ready to field millions of n00b questions about it

I would think a Centrifical super charger would be easier to work with......

That's true it would be, however to me a centrifugal supercharger offers all the negatives of turbocharging, along with the negatives of supercharging. So it's like the worst of both worlds.

I mainly wanted to go with a roots style blower to see if the increase in torque will be as dramatic as i'm led to believe.

there is a picture of a centrifugal supercharged neon around here somwhere, I think Mattdog has it. But that would be too easy anyway

Centrifugal would have been too easy!

If this project goes much furthere you will need to change your screename and your location.

Sweet project though.

Bob

Mine had a bolt on plenum with a tube output, guess yours doesn't

Well I'm still saving some cash to purchase my tig welder, so in the meantime I installed my cam and cam gear over the weekend.

Here's a few pictures of the install:

Sorry some of these are so blurry,

First off it's definitely true that you can change the cam in a SOHC without removing the head, you really don't even need to tilt it that far upwards.

here it is with the old cam out


New cam in


rocker arms reinstalled


here's the gangster way of compressing the tensioner


here's a sight that neon owners see way too often!


For some reason my finished pic won't show up, but basically it looks exactly the same as before, just with a different cam gear. Haven't gotten to really run it out yet to see if it made any noticeable difference, but we'll get all that nailed down later.

I also got another important part of my build in the other day.


I started on the intake manifold as well, I'm waiting until the supercharger is mounted before I get final dimensions on this, might cut it down just a bit further.






here's another picture of the supercharger for the one who asked for it.


That's all the updates for right now, hopefully I'll be able to get started on mounting the supercharger soon. that's the most important next step to get this moving.

Let me know what you think so far!

ok i dont know superchrgers at all so im sorry if this is a stupid question but were is ur throttle body at?

no question is off base when you're doing something completely custom

I'm making a custom boxed style intake manifold and that's where the throttle body will mount, the round section of the supercharger will simply be the air inlet, the discharge side which is the square section will dump into a tube going to my front mount intercooler which will then route to my intake manifold, due to this design I'm going to have to run a BOV, probably a first gen DSM style.

Although I am still trying to figure out if I can plumb in the factory bypass valve for idling and such. not sure If i'm going to have the room.

thanks for the question

EDIT: Received a great PM that showed this design idea to be flawed. The throttle body will now be mounted in front of the blower instead of downstream as originally planned.

oh ok i get it

I'm trying to fab up some templates for brackets to mount my supercharger.

Unfortunately, it's not as simple as tracing the pattern, the design of the charger prevents that, so first I tried cutting a template out of cardboard, but it still wasn't perfect, and I don't want to waste a bunch of metal when I cut out the real bracket. So I'm at work today trying to think of a better method, when suddenly it comes to me: Plaster mold!

Thus the following is the creation of the perfect template, enjoy O0

the first try with cardboard



tape of the area I needed


construct the box


Here is the secret ingredient, to getting it to come apart at the end


Poured and smooth


hardened and removed



Look at that fit, better than anything i could have cut myself, now I've got a perfect template for cutting out the real thing.



Clean the tape off of the blower, ta da! looks good as new.


thanks for checking it out.

Wow, plaster mold... thats a pretty damn good idea.

One thing, I take it you're going to have to make a custom bracket for the supercharger's outlet?

Interesting build!

It's about time someone got away from the usual turbocharger and started turning some rotors!

Thanks for the comments so far

Yes I'm recieving my tig welder in a couple of weeks and when that gets here is when the fun really starts. You'll get to see what I have in mind for the outlet discharge then.

please keep the comments coming, I'm enjoying doing this and any replies are greatly appreciated.

Im glad to see someone finally doing this... maybe make extra brackets and stuff and sell them later so other people can do the same thing

*clicks*

Subscribed. Awesome build..nice to see something with thinking out of the box that's actually being done!

And spoil my exclusivity?

Not sure that would be a great idea anyway because honestly there's going to be so many one-off parts to get this to work, besides as was pointed out earlier- the blower I'm using isn't exactly the best one out there

Once I get the setup working good then I'll probably step up to a better blower, perhaps a screw model.

ooooh, i want that book 8O i bet thats some good reading.

nice looking build

a good boosted supercharged neon would be to much fun on the street.

gobs of low down torque. be a good combo for a atx

hum hum hum... Dooby dooby do.. Ah.. eh? Oh what do we have here... Looks like my lil brother parked in the wrong place.. Lets see your little supercharger save yah now! Ah hahahha!



Outta gas again, Damn.

Nice, real nice

he'll have to catch me first.

any updates?

Yes, sadly......... http://forums.neons.org/viewtopic.php?t=259733

damn your project looked promising =(

Oh damn I came here to see some more pics

awww I wanted to see this one go thru.. maybe pick it up again later

Good news people, I was pretty *a#S!d^f* because I really wanted this to go through.

Needed money, but alas, good intentions prevail and I was able to sell my truck. I'm still looking to sell the cam and cam gear and gauge cluster pod, but I'm going to finish this project!

I realized that I'm at the point where it's mostly fabricating work that needs to be done right now, and that I can handle

I'll get some pics up soon.

OK then here's a couple of the things I've been up to lately. Sorry I haven't posted in awhile, I'll try to stay more on top of this thread

First off, I did some grinding on my intake manifold to both clean it up for welding and to clean up the castings, not done yet, but this is dirty annoying work



Next I've been working on mounting a 6-rib pulley to my stock power steering pump. People who say that I should just ditch PS should shut up! I did get rid of it last time with my turbo kit, and even with a limited slip diff in this car, if anyone has ever driven a turbocharged car with no PS and hit ruts in the pavement with 205 tires, they know one thing. Power steering is where it's at

Ok on to the multitude of blurry pics, sorry bout that but I need a tripod for my digital For anyone who wants to know what a neon PS pump looks like apart, here you go.

Here's what it looks like factory


you remove the five bolts at the back


Here's what you're looking at


You remove the outer collar and that exposes the vanes of the pump. Pretty interesting design, the vanes simply fall out when the collar is removed, so try to keep track of them.



to remove the pulley shaft you must remove the c-clip on the end of the shaft


You can then slide the shaft out and remove the pump vane assembly.
Here you can see the vanes sliding out.


Here's what's left. Pretty simple but effective design.


Here's a couple shots of the pulley I'm trying to adapt to this pump.



as you can probably tell from the pictures, the shaft of this pump is welded to the pulley, now I've heard that there are neon pumps where the pulley can be removed, if anyone has any information on these I'd greatly appreciate it, because if not I'm going to have to do this the hard way. Welcome to my plasma cutter



The hard part about that is that I'm sure you can tell the new pulley I have is aluminum, and I can't just weld it on like the stocker, plus I'm going to have to machine the hub a bit to open it up enough to fit over the stock shaft. Could be interesting to do, but I'd much prefer to work with a removeable pulley. Someone give me a shoutout!

Most of the reason It's been a little while since an update is because I was waiting to get this all setup.
Everyone loves a tig welder


Oh yeah I'm a stunna now.


and I finally got a vice and some welding magnets that'll come in handy once I get some metal to start fabbing things up.


Thanks for sticking with me on this one, and I hope to get some more regular updates for you guys.

sky

SWEET!!!! back from the dead and goin strong sweet nice build

YAYYY!!!!!!!!!! WOOOHOO!!!!!

Can't wait to see this one done!

I tried to get the pulley off too with a puller and all with NO luck. Look under the group buy / dealer area for my user name and "aluminum pulley"... somebody mentions they have gotten theirs off before (If I rememeber correctly)