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Supercharged Dyno run

Discussion in 'Subaru Sambar' started by banzairx7, Mar 12, 2020.

  1. banzairx7

    banzairx7 Active Member

    Brought the truck in for it's baseline dyno run today. 51hp, 50tq are the peak numbers. Two other important things learned. One is the intake temps skyrocket after just one run and drop the power significantly. We were seeing 42-44hp on runs were the truck didn't sit for a while cooling. It also runs VERY rich. It was all the way down to low 10:1 air fuel ratios in the upper RPM's.

    I've got an intercooler already and just waiting on some more parts and that will be going in. I'll also need to adapt a power commander from a motorcycle to it to lean out the fuel. I've used them on a few cars and they work great for adjusting fuel.

    [​IMG]
     
    Limestone likes this.
  2. Limestone

    Limestone Well-Known Member

    banz,
    Great info. and insight here! Thanks, I'm sure others will agree!
    Limestone
     
  3. Adam Wheeler

    Adam Wheeler Active Member

    Air boxes on these things are quite restrictive for top end as these don't seem to be ever designed for that in mind, there is also an ACT on the bottom of the air box I believe, that might also be playing into that. What was AFRs at idle?
     
  4. banzairx7

    banzairx7 Active Member

    We did a run with no airbox and besides the wicked sound of supercharger whine it made no difference. I kind of expected it would. I've got an idea to make a much shorter run to fresh air than through the entire length of the frame. Might not add power but the sound of the supercharger is pretty damn cool IMO.

    What is an ACT? My box just has some vacuum/vent lines going to it.
     
  5. Adam Wheeler

    Adam Wheeler Active Member

    On the inside of the box some have an Air Charge Temperature sensor, maybe its just the later models or just carb versions as the carb version also has 2 hoses from the exhaust running into the airbox as well which I dont believe the sc versions have.
     
  6. rkrenicki

    rkrenicki Active Member

    That is pretty close to what I was seeing, but I was getting 49-50hp consistently over 5 runs. I did not run an open airbox, so perhaps that is why it was more consistent for me. Here is my graph, I could only put 4 of the 5 runs on here for some reason. The guy running the dyno didnt want to go all of the way to 7.25k

    dynorunShare.png
     
  7. banzairx7

    banzairx7 Active Member

    I only did one run with the air box open. Wonder why yours was so much more consistent? I ran mine right up to the rev limit which is 7800rpm if anyone was wondering.
     
  8. SDK1968

    SDK1968 Active Member

    im just guessing that you just have too much fuel in the mix.

    bet when you lean it out it will gain some.

    kinda shocked though......... you guys are only getting 49hp with a supercharger? thought the guys with the snowmobile set ups were getting 70ish?
     
  9. banzairx7

    banzairx7 Active Member

    This motor is only a two valve head, no intercooler and low compression. More modern stuff runs higher compression with 4 valve heads and an intercooler which makes a huge difference. My guess is an intercooler and leaning the mixture out gets me to 60.

    They did make a 4 valve head on the EN07X engine. I haven't been able to find if anyone has swapped the engine or head into a Sambar.

    [​IMG]
     
  10. rkrenicki

    rkrenicki Active Member

    Yep, they went low compression so that it could run on normal fuel in Japan while remaining forced induction. The EN07X from the Vivio RX-R, I am fairly sure required Premium (100RON) fuel.

    The supercharged engine is tuned mostly for the early and very flat torque curve. It does make a little more HP than the carbed version, but the torque is quite a bit higher and comes on much lower.
     
    Limestone likes this.
  11. rkrenicki

    rkrenicki Active Member

    I do not know. This was shortly after a complete engine rebuild, so perhaps the fact that all of the mechanical parts were new helped with the consistency. Nearly every part was replaced.. The block, oil pan, and 3 of the piston crowns were all that remained of the original engine. This dyno run was about a month later after the break-in period was over, and the rings had time to seat.
     
    Last edited: Mar 20, 2020
    Limestone likes this.
  12. banzairx7

    banzairx7 Active Member

    New supercharger outlet got started yesterday. Might have it done to try and get the intercooler in this weekend.

    [​IMG]
     
    Limestone likes this.
  13. banzairx7

    banzairx7 Active Member

    Turning this into my power mods thread too. Got the Power Commander 3 USB installed yesterday. The power commander basically splices between the ECU and the injectors and allows you to adjust fueling via a laptop. Once I figured out what wire did what it was pretty straight forward. One thing I discovered is the online manual that has the ECU wiring has the throttle position sensor completely wrong. Everything else seems to check out but that. Here is the wiring for the power commander. Since they don't sell this for anything but motorcycles you'll need to wire it in yourself. For now I pulled out 15% fuel above 50% throttle. Once the intercooler is in it'll be back to the dyno to really tune it.

    upload_2020-3-29_15-27-1.png
     
  14. banzairx7

    banzairx7 Active Member

    Intercooler is in. Ran into a few issues that I need to resolve. First is I hard bolted the cooler to the bed of the truck. This coupled the supercharger noise to the bed and amplified it like 20x. It is SOOO loud. Rubber isolation bushings on the way! I tried running the straight sections of hose with just silicone hose. It's collapses hard on itself under vacuum. Need to replace it with some stainless tube. Still need to add a scoop to grab air from under the truck.

    As far as effectiveness of the intercooler it definitely helps. Power is more consistent as well as boost. Runs consistently about 7psi now. Before when things got real hot it would go as high as 10psi. The hot air expands so the extra boost from it doesn't help power.

    supercharger outlet adapter. My Lotus 7 kit car is hiding in the background.
    [​IMG] [​IMG]

    Intake manifold adapter pipe. I had the flange laser cut from stainless. The bracket is for the throttle cable.
    [​IMG] [​IMG] [​IMG]

    Intercooler. Brackets were also cut by the good folks @ sendcutsend.com can't recommend them enough.
    [​IMG] [​IMG]
     
    Adam Wheeler likes this.
  15. rkrenicki

    rkrenicki Active Member

    Hopefully all of that extra intake volume isnt a problem for the tiny supercharger. If it is, you may want to step up to an AMR500, or perhaps undersize the pulley.
     
  16. banzairx7

    banzairx7 Active Member

    I had the same worry about the added intake volume. If it effected the truck I couldn't notice. Boost comes on just as quick before.

    I have two smaller pulleys ready to go for it also. 58mm and 52mm diameters. Stock is 61.5mm.
     
  17. banzairx7

    banzairx7 Active Member

    Intercooler scoop is on. Going to the dyno on tuesday to tune the motor with the intercooler.

    [​IMG] [​IMG]
     
  18. Ohkei Dohkei

    Ohkei Dohkei Active Member

    That should be really interesting I'l guess 56. Can't wait to see.
     
  19. Reese Allen

    Reese Allen Member

    Yeah, this is a super cool project. I wish I had the fab skills (and equipment) to do this sort of thing.
     
  20. banzairx7

    banzairx7 Active Member

    MUCH better than expected results. Truck makes 59hp all day every single run. Originally it peaked at 51hp for one run then heat soaked down to 44hp. We probably did a dozen runs tweaking the A/F and it never heat soaked one bit. Below 5k air fuel wasn't too bad. After that had to increasingly pull fuel. Over 7k rpm had to reduce fuel by 22%! It now makes power right up to 7,500rpm and just drops a little bit up to the rev limiter @ 7800. I was thinking I might make 65hp when all is said and done. 70 might be an achievable number.

    [​IMG]
     
    Last edited: Apr 15, 2020
    Adam Wheeler likes this.
  21. Ohkei Dohkei

    Ohkei Dohkei Active Member

    Nice! is that with the stock pulley?
     
  22. banzairx7

    banzairx7 Active Member

    Yes stock pulley. Turns out the two pulleys I had waiting in the wings had the wrong bore size. They were for the AMR500 supercharger. I assumed they were the same. I have another pulley due in tomorrow that I hope I can mod to work.
     
  23. banzairx7

    banzairx7 Active Member

    Got the new pulley on tonight. New pulley is 55mm OD and the stock one was 61.3mm. Boost went from 7psi to 9psi. Power is most noticeable at low to mid throttle. Was able to buy an alternator pulley and modify it to fit. It needed a spacer to go behind and had to have a keyway cut in it. I also had to put on a shorter belt. I could put this into kit form if there was interest.

    [​IMG] [​IMG] [​IMG]
     
    Limestone and Ohkei Dohkei like this.
  24. willoh

    willoh New Member

    I am very interested in the complete intercooler setup as well as the tuning maps as soon as you work out the kinks! PS I have a 95 Dias with the EN07Y and I assume the engine setup is identical with the truck one
     
  25. banzairx7

    banzairx7 Active Member

    This intercooler set up is kind of complicated and I'm not sure it would fit a van. I'm into it for probably $500 + my time so not cheap. I've also found it does require a fan which I'm in the process of adding. That means I need to add some kind of control for it. I've got a pressure switch and time delay relay on the way. The time delay relay will keep the fan from cycling off and on constantly. Basically when you hit boost the fan will stay for like 10 seconds regardless of what the boost is doing.
     
  26. Jigs-n-fixtures

    Jigs-n-fixtures Well-Known Member

    Just out of curiosity: Why aren’t you using a thermostatic switch. Set up so that if teh temperature on the exit header of the inter cooler is however hot, the switch closes and the fan comes on. The switches are pretty inexpensive, and readily available.
     
  27. banzairx7

    banzairx7 Active Member

    I had that thought too. Problem is by the time the intercooler would be hot enough to trigger the switch I'd be behind the curve. Everything would already be hot. If I go by boost pressure I'm cooling before it gets to the point the heat starts hurting power.

    Honestly I keep inching closer to ditching the stock ECU for reasons like this. If I had an aftermarket ECU I could use the air intake temp sensor(or MAP sensor for pressure) which reads really quickly to trigger the fan.
     
  28. banzairx7

    banzairx7 Active Member

    Was back at the dyno yesterday. Since my last runs I made an intake, got the intercooler fan set up working and put on the smaller supercharger pulley for ~1.5psi more boost. Results were up but a little lower than what I expected. I'm now @ 62hp at the wheels. I think either the throttle body or exhaust is a bottle neck at this point. Not that 62hp isn't great for this little guy. That means I'm making ~73hp at the engine and stock it was rated at 55hp. A 30% increase in power is pretty good.

    The last few weeks I've been trying to figure out what to do with the exhaust. Where I ended up is if I'm redoing it from scratch I'm just going to replace the supercharger with a turbo. The supercharger right now is really loud so that's reason one. I'll make more power at the same boost level with a turbo. They are more efficient and I won't have the parasitic drag of the supercharger. Last thing is turbos just make super cool noises! I ordered up a RHB3 knock off turbo, it is tiny. Compressor map though shows it's a good match for this motor. At 10psi of boost and peak power @ 7k rpm I'm right in the sweet spot of the turbo.
     
  29. SDK1968

    SDK1968 Active Member

    you are a true tinker-er!

    love reading your stuff & going: man thats way toooo involved for me. :)
     
  30. Reese Allen

    Reese Allen Member

    10 psi of turbocharged intercooled boost would be massive.

    While you're going crazy, why not go with an air to water intercooler system, and put its radiator up front where it gets max airflow? I see lots of room for one behind the grille of my '93...
     

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