Supercharger Installation!
 

Ohio Boxster is going to share with us his experience in this very interesting topic!

Go Ohio!!!!!!!!!!!!!!

Ok, thanks. I think it would be best to start out with a price list. This is what I have spent to date.

Supercharger price list:

Supercharger kit..........$ 1398.00 includes shipping
Brass nut.....................$ free 00 guy at home depot gave it to me
Metric fastners.............$ 38.00 Bolt depot (studs,nuts,washers,etc)
Loctite flange sealant..$ 25.00 Online (couldnt find it locally)
Vacuum hose...............$ 4.00 Auto Zone
Tee-fitting....................$ 1.99 Auto Zone
water hose 1"..............$ 11.00 Auto Zone
Dayco belt....................$ 36.00 Advanced auto
Digi box (fuel box)........$ 500.00 TPC
Injector........................$ 100.00 TPC
Fuel line.......................$ 50.00 TPC
Install manual..............$ 00.00 TPC (gave me manual free)
Shipping 4 ^.................$ 20.00 Ups
Air filter.........................$ 22.00 Pelican
Fuel filter......................$ 38.00 Peliican
2" Silicon hose..............$ 25.00 E-bay 2 total S&H in price
Supercharger oil............$ 14.00 Pontiac dealer (2 bottles)
Boost Gauge.................$51.00 Auto Meter


Misc money:

Mobil 1..........................$ 57.90 Auto Zone
Oil Filter........................$ 13.00 Sunset
Ignition switchs............$ 36.00 E-bay (2 total)(no labor $)
Clutch line.....................$ 63.00 Porsche dealer (no labor $)
Brake fluid.................... $ 5.00 Auto Zone
Plug tubes.....................$28.50 (6 total) Pelican
Plug O-rings..................$31.50 Pelican (Inner and outer)
Pollen filter....................$13.00 Pelican
Super Blue brake fluid...$14.00 Pelican (bought this to get free shipping)
http://i5.photobucket.com/albums/y17...ter/blower.jpg
http://i5.photobucket.com/albums/y17...ter/piping.jpg

Good luck.

Are you doing the install yourself?

Yes, the week of 09-04-06 Im off work for a few weeks and should have all the parts to finish.

Very Cool.

Can I suggest some M1 15W-50 or Red Line of the same weight. I worry about that engine under pressure.

I could be being too cautious.

Very cool mine will be done on the 11th from what I am told!.......Photo shoot for Excellence on that day :)

Excelence will be shooting tthe 3.8 transplant into a 2000 986 S that FVD in FL did this month....GO 986'S


Good luck with the install and have blast after....But please do me one fav before the install....Do a combustion chamber test on each cylinder....Just to be safe

An update
 

This is a pic of me admiring my soldering work. I soldered all connections and used shrink tubing where I could. As you remember the Digi box was installed but not wired. Last night I started to wire it and finished up today. http://i5.photobucket.com/albums/y17.../soldering.jpg

This is the wiring harness that I need to tap into, Im looking for the violet and green wire along with the red and blue. One is the tach signal the other is 12v switched.
http://i5.photobucket.com/albums/y17...er/trim001.jpg

Its pin 54 and 80.
http://i5.photobucket.com/albums/y17...er/trim002.jpg

Here they are.
http://i5.photobucket.com/albums/y17...er/trim003.jpg

update cont....
 

This is the pic after I taped into the harness, soldered the wires and rewraped.
http://i5.photobucket.com/albums/y17...er/trim004.jpg

Now its all wired and reinstalled, looks pretty good huh?
http://i5.photobucket.com/albums/y17...er/trim010.jpg

This is where I ran the wires and vacuum line into the engine bay. Dont worry nobody will ever see the holes.
http://i5.photobucket.com/albums/y17...er/trim007.jpg

These are the additional fuel injector wires that go to the box in the trunk. I zip tied the out of the way after soldering the connections. The box is all wired ready to go.
http://i5.photobucket.com/albums/y17...er/trim009.jpg

This is the fuel regulator that I need to tee into and run a vacuum line into the trunk to the Digi box. As boost increases the box fires the 7th injector.
http://i5.photobucket.com/albums/y17...er/trim006.jpg

There, I teed into the vacuum right here.
http://i5.photobucket.com/albums/y17...er/trim005.jpg

I still need to tee into the line again for my boost gauge. I will decide where after the gauge gets here and I figure out where to mount it. This final picture is the box behind the carpet. You will never know its there.
http://i5.photobucket.com/albums/y17...er/trim011.jpg

Sorry if this appears to be going backwards. I wasnt allowed to post all the pics in one post. Im not real sure how to correct that. I think getting the box all wired will save alot of time toward the end of the install. This is actually the last step in the install manual but I realized when I posted the price list I failed to order the O-rings for the spark plug tubes. I ordered the tubes as well, If Im going to be that under there and have the plugs out I might as well change them too. I took the car for a test run and I didnt freak the computer out. I was a little worried but it ran great. Next I will take pics of the boost gauge install. I would welcome suggestion on where to install it.

nice work, is the supercharger installed on the box yet? if so, any pictures?

Thanks, No this is a play by play. Pretty much what you see is my progress up to date. The install date is 09-04-2006, thats when I start vacation and I can just take my time.

hehe
 

I'd like to know how you convinced Vin Diesel to install your supercharger?? :)

Kind regards

I have to admit I was thinking the same thing....Ohio, you are one badass looking mofo. If anybody says the boxster is a chick car I will just show them your pic and that should squash any issues lol. Anyway back to the install this is good info. What kind of boost are you expecting to get out of this thing? Are you going to throw it on a dyno when it's done?

Its supposed to be only like 4.5 lbs of boost which is ok for me. My plan is to take it to the dyno to make sure my air/fuel is correct. The Diesel comments cracked me up, I try to stay in half way decent shape. The Boxster is no chick car,lol.

Try to stay in half decent shape? Dude, your shoulders are bigger than your head!

lol, but his head is shinier :D

Heres the gauge, it came today. Now to find a mounting location. This will match my silver face gauge cluster. Yes, my head is shiny, just polished.
http://i5.photobucket.com/albums/y17...r/100_0543.jpg

Boost gauge install
 

This is where I would like to install the boost gauge but I started to think long term. If I sell the car with no blower then I have a hole in the dash, you never know.
http://i5.photobucket.com/albums/y17.../blower003.jpg

This is where I tee'd into the vacuum line, zip tied in a few spots to keep it from moving around.

http://i5.photobucket.com/albums/y17.../blower004.jpg

I ran the vacuum line under the center console and zip tied it to existing wires.
http://i5.photobucket.com/albums/y17.../blower005.jpg

This is where I ended up putting it.

http://i5.photobucket.com/albums/y17.../blower006.jpg

Gauge functioning at idle, still need to wire light had to break for some chow.
http://i5.photobucket.com/albums/y17.../blower007.jpg

Todays update
 

Although not exciting it was necessary. I cleaned all the machined surfaces that mate and the duct work. Found a few spiders living in my pipes.
http://i5.photobucket.com/albums/y17.../blower008.jpg

Getting the blower cleaned up.
http://i5.photobucket.com/albums/y17.../blower010.jpg

This is the oil for the blower, I ended up using probably one and a half bottles.
http://i5.photobucket.com/albums/y17.../blower009.jpg

This is what the spark plug tubes look like that Im going to replace along with o-rings, if your interested.
http://i5.photobucket.com/albums/y17.../blower012.jpg

I changed my cabin filter, look how dirty.
http://i5.photobucket.com/albums/y17.../blower011.jpg

Yeah man, Ohio your about 3 sets of 10 from shoulder muscles growing on your shoulder muscles! :cheers:

Any news or updates? I'm anxious! :eek:

No, still seven more days until I really get into it. I had to buy a 24 mm wrench and new low profile floor jack. Pretty soon, so keep checking back.

Update with pics.....
 

I started about 12:30 today and by 2:30 I had the SC unit in place. Then it came to direction #5 on my install guide...Snake pipe 4 up through engine and chasis. It should have said draw a pentagram on the ground and sell your soul. The one pipe you can see through the wheel well took me 4 hours to install, hmmm I guess thats why its called pipe #4. One of the bolts took forever ! No room for a wrench or socket. I changed the 3 plugs on the passanger side today. I need the proper water fitting (see pic one) for the line that needs rerouted. Tomorrow is another day....
Water line...
http://i5.photobucket.com/albums/y17.../blower013.jpg

Take this off, rear cross member.

http://i5.photobucket.com/albums/y17.../blower017.jpg

Remove this bolt to swing trailing arm out of the way.
http://i5.photobucket.com/albums/y17.../blower018.jpg

These are the bolts that you take out to mount the SC braket to....

http://i5.photobucket.com/albums/y17.../blower015.jpg

Replace bolts with studs use antiseize.
http://i5.photobucket.com/albums/y17.../blower016.jpg

Continued...
 

This is the SC unit bolted to the exhaust manifold
http://i5.photobucket.com/albums/y17.../blower021.jpg

This is the unit pretty much in place ....
http://i5.photobucket.com/albums/y17.../blower020.jpg

Looking at unit through wheel , evil pipe 4
http://i5.photobucket.com/albums/y17.../blower019.jpg

back view

http://i5.photobucket.com/albums/y17.../blower022.jpg

All thats left underneth is bolt the sc unit in place, pull some lines out of the way, reinstall trailing arm and crossmember, fuel filter, drivers side plugs, shileding. I think thats it, sorry for fragmented sentences, kinda tired. The car kicked my butt today.

Ohio, did you use different spark plugs and gapping to accomadate the new s/c?

Reading this post is like watching a good tv show! I look forward to next week's episode.

Adam,
I spoke to the owner of TPC and presented the same questions to him. I would think you need to run a heat range colder and close the gap some. Tom, the owner assured me that factory plugs are just fine.

Jeph,
Im glad you like the thread. Tune in tomorrow I hope to get alot more done. Im thinking two to three days should do it.

Todays update
 

Today I woke up at 5 am. and went out to the garage at 6 am. I was not looking forward to crawling back under the car this morning because my back was aching.
I acomplished quit a bit today. Installed the drivers side plugs, fuel filter (kinda a pain in the butt) zip tied some air condition and water lines out of the way. Next I tightened up the SC unit and now its in final resting position. Installed three more pieces of duct work (see pics) this means I have only two to go. Rerouted the throtle cable under the manifold, extended the electrical wires 14 inches (6 total and soldered the connections) and reinstalled the trailing arm. I probably forgot a few things if I think of them I will post.

This had to come out.
http://i5.photobucket.com/albums/y17.../blower026.jpg

This pipe had to come out.
http://i5.photobucket.com/albums/y17.../blower025.jpg

Installed bypass valve on this pipe.
http://i5.photobucket.com/albums/y17.../blower024.jpg

Had to remove this bracket from throtle body.
http://i5.photobucket.com/albums/y17.../blower027.jpg

Two more pieces of duct work installed.
http://i5.photobucket.com/albums/y17.../blower029.jpg

This is where I need to tap into fuel rail.
http://i5.photobucket.com/albums/y17.../blower030.jpg

Throtle body repositioned, rewired and more duct work installed. My arms look like I got into a fight with a blender. Talk about tight clearances.

Ok, this is a pic of the throtle body, wires etc.
http://i5.photobucket.com/albums/y17.../blower031.jpg

There is a good chance I will be done tomorrow. Spent about an honest 8 hours working on the car today. 10 1/2 hours todat total but I broke for lunch and had to make a parts run. I probably have an overall total of about 20 - 24 hours I cant really remember how long it took me to wire the fuel box. The way I look at it is the fact that my 60k mile service will be done as well. I killed two birds with one stone. Im going to try to catch the first time I start it on my video cell phone. More updates tomorrow.

I pretty much finished up today, just need to put the plastic shielding back on. When I first started up the car it idled kind of rough but then smoothed out. I had a vacuum leak but I think I took care of that, will know later. Going to the store to get some starting fluid to make sure leak is gone. The rpms would hang around 3k for a few seconds after I would let the gas off, really frustrated me but figured out the cable wasnt on properly. I fixed the throtle and took it for a few short drives. It has more power down low and has a cool little whine. Its not nearly as loud as IA's supercharger but still cool. I was afaraid to get on it until Im sure fuel isnt a problem. Check out pics and I have a cell phone video I will try to link to. All and all it went pretty smooth, Im happy with it. I've been reading other threads and people just cant figure out why you would want to Supercharge a Boxster so Im going to tell you. I have under 2500 bucks in this set up. It was either Wheels or Blower, for me that was a no brainer. No, Im not trying to build a Viper killer by any means. I did it for the cost and challenge, I won this round. To wrap it up the car seems to be running great, no detonation and its really cool when the blow off valve is functioning. Pssssssh psssssh, Cool. I hope to share the video even though its a crappy one because I was driving but if someone can put them up somehow I will email them to ya. Thanks for following along! Three days, not bad huh?!

This is where I tap into fuel supply.
http://i5.photobucket.com/albums/y17...lower030-1.jpg

Duct work under car.
http://i5.photobucket.com/albums/y17.../blower035.jpg

Cut the J-tube ran to duct work.
http://i5.photobucket.com/albums/y17.../blower037.jpg

Had to plug the hole in the manifold, this is where the J-tube was located.
http://i5.photobucket.com/albums/y17.../blower038.jpg

Fuel line hooked up.
http://i5.photobucket.com/albums/y17.../blower036.jpg

See if you can use a digital camera for video clips. I bet they'd be better than the phone's video. Entertaining write up! Good job.

Thanks Jeph, its running very well now. I found a small vacuum line that had a cut in it. The videos are really small and play with quick time, if you want I will send it to ya.

Ohio - you are SO the man! :) Awesome work!!

If I had a hat on right now, it would be tipped in your direction.

Kind regards

Nice work Ohio!!! I know you don't have a baseline setting on the ole dyno, but how about taking that thing in there now just for ****************s and giggles to see if you have boxster S power or more?

Now Im happy !
 

The car was running good now its running great! You know it was only reading 2 lbs of boost at the gauge so I thought maybe the gauge just wasnt working correctly, nope. I took a can of either and sprayed the intake, throtle body, each individual piece of duct work and then it happened. Vrooooom, ah a leak. So I worked on what I thought was the leak for about 2 hours but it still would rev when I hit it with either. I finially figured out that the either was misting the next junction(see pic). The pipe somehow got a flat spot in it. So I used a big socket with an OD that matched the ID of the duct work and knocked it back round. Had a pic of that but my camera died. The car runs like factory now, just purrs. It has a much more sensitive throtle now that boost comes on much sooner since its not venting into the atmosphere.
My wife reminded me why I married her the other day when I was working on the car on our anniversary. She said "I cant wait to hear how this sounds" talk about support.

How in the heck did I miss that? Oh wait I know three straight days under the car!
http://i5.photobucket.com/albums/y17...ger/blower.jpg

Is there a boost gage inside the cockpit?

Yes, scroll down and see pic.

Sorry, I missed that. Very cool! I think I would be looking at it all the time!

Ohio, I think you said that you plan to run 4 pounds boost....but, the gage looks like it goes from 0-30. Wouldn't you want a gage that was, say from 0-10 so it would be more accurate and easier to read? Maybe I am missing something. Thanks.

Great work & right-up.

Well the gauge now appears to be accurate but a bigger display that went to 10lbs would be nice. The left side of the gauge is vacuum the right is boost 0-20 lbs.

Thats the part I dont think people understand. The car operates normaly in a vacuum state until you get into the pedal. So the blower doesnt ruin the car the driver does. I have read so many threads about SC blowing up motors. If my car blows up its my fault, period. I drive my cars pretty easy.

@ OhioBoxster, if I were old enough to toast a beer to you,I would. Congrats on one heck of a D.I.Y.!