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Hawk's Mk1 Supercharge Project


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#381 B_hawk111

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Posted 02 June 2020 - 07:32 AM

Nice work as always.
Why did you remove the ABS?


Main reason is it really limits the space for the supercharger inlet!

Bit it's also heavy, a bit useless, and in 5 years its only helped me twice, both times in winter, both tines in the rain.

Both of which I don't do any more 😉
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#382 B_hawk111

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Posted 02 June 2020 - 09:13 PM

A bit more done today!

My coil pack wiring loom has been a bit dodgy for a while. Both clips have snapped off, and I had to repair a wire last winter!

So I have replaced the coil connectors with ones from a spare loom, and then tidied up the rest of it!

49964132738_2ede78f966_c.jpg20200602_132913 by ben hawkes, on Flickr

And then came up with what I thought was a clever idea to fill the gearbox oil

49964132578_7e8f719fd7_c.jpg20200602_154502 by ben hawkes, on Flickr

49964636061_2e1ca5f96c_c.jpg20200602_154524 by ben hawkes, on Flickr

Hard pipe makes it easier to position the pipe and the bottle just glugged away into the pipe!

Also got the Mk2 throttle body cleaned up, bolted and connected up, then fitted up the rest of the coolant pipes, wiring and vac pipes!

49964132288_88c0548542_c.jpg20200602_160319 by ben hawkes, on Flickr

Should be ready to refill the coolant tomorrow, give the brakes and clutch a final bleed and get the manifold in the spray booth for ceramic coating!

I gave the exhaust tip a quick clean up and fitted back on,

49964132428_69d853dfc4_c.jpg20200602_173713 by ben hawkes, on Flickr

I'm also attempting to get the VSS working on the me221, I think I've worked it all out, just need to try and work out which input on the ecu to use!

Also turns out a dewalt drill will run the speedo at 80mph 😂
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#383 B_hawk111

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Posted 03 June 2020 - 01:36 PM

Popped into work and got the manifold in the spray booth!

49966429528_5dfcb7474d_c.jpg20200603_113510 by ben hawkes, on Flickr

I was hoping to give this to a friend to ceramic coat, but due to covid he lost his job which is terrible for him!

He was kind enough to put me onto the ceramic paint they used at his firm, and it turns out it comes in all sorts of colours!!

49967210397_9602499f50_c.jpg20200603_113706 by ben hawkes, on Flickr

Isn't cheap stuff, but it only takes one coat, so the exhaust is done, and I've still got over half the tub left! So once I've modified the intercooler pipes, they are getting the same treatment!

49966429483_7480b23be8_c.jpg20200603_115508 by ben hawkes, on Flickr

Should help keep the engine bay temps down! And I really hate exhaust wrap so solves that problem too! Still going to run the TDR manifold blanket as before, although that is not looking too good!
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#384 carl s

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Posted 03 June 2020 - 07:54 PM

love it!

 

49964636061_2e1ca5f96c_c.jpg


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mk1 1991 Eunos with RS NB drivetrain: https://www.mx5nutz....howtopic=322586

ex - mk3 2006 2.0 sport

ex - mk2 1999 1.8is JRSC


#385 B_hawk111

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Posted 03 June 2020 - 08:55 PM

love it!

49964636061_2e1ca5f96c_c.jpg


Simple eh!! Worked great!
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#386 B_hawk111

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Posted 03 June 2020 - 09:25 PM

So more new stuff arrived today!

Well I say new! Very dirty and well used! But super cheap!

49968185746_40313847e8_c.jpg20200603_193534 by ben hawkes, on Flickr

Gave it a good clean up and then stripped it apart to check the spring!

49967673168_49742a4f48_c.jpg20200603_194947 by ben hawkes, on Flickr

Must have been running some big boost, had a blue spring in which is rated for 23-30psi apparently!

I've ordered the green spring which is good for 6-15!

Just need the pipe to turn up so I can get it welded on!

Oh and after a bad start with a dodgy paint gun, I've borrowed the decent gun from my work and got the hardtop in epoxy!

49967673153_e403273b3f_c.jpg20200603_204232 by ben hawkes, on Flickr

Will need some serious sanding tomorrow to get the first guns attempts at ruining it off, but should be in filler primer before tomorrow evening! And hopefully the car will be back up and running too!
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#387 Shadowraven

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Posted 04 June 2020 - 11:07 AM

Bit more done today!

Old clutch out!

49953438161_ae23aacd97_c.jpg20200530_114328 by ben hawkes, on Flickr

 

So what I'm hearing is you are well practiced, want to help me do mine on the track car? it's a 50k mile super clean car lol


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UKDM 1998 1.8 Mk2 Sport - Current mods-  Custom 6 point chassis mounted front splitter and sideskirt extensions, battery cut off switch, OEM 'small skirts' and lip, HEL braided brake lines, OEM front upper strut brace with MC brace and mazdaspeed sticker, custom made 2" high flow catback exhaust, Japspeed 4-1 exhaust manifold, Lorber 15" alloys in fiat 750 maroon volcano, uniroyal rainsport2s, Ebay special JDMyo! gear knob, tinted indicators, colour coded reflectors, black headlight inserts, LED sidelights, SMD number plate bulbs, dimpled and grooved mtec brake discs, mintex brake pads, de-tango'd headlights, amber bulbs, RGB footwell lights, SMD interior light, Deltastyling spoiler, foamectomy seats, mazdaspeed seat belt pads, ring ultimax headlight bulbs, IL Motorsport style bar in custom paint, ford fan washer jets, Skidnation coolant reroute with Kia thermostat housing, Gates 22436 radiator hose with hose bracket, 82/85 degree twin valve thermostat, D1 spec engine bay dress bolts, stainless steel bolts throughout engine bay, EGR blanking kit, painted brake calipers, painted tow hooks front and rear, wrinkle painted cam cover, de-greened dials with white SMDs, red needles, painted cigarette lighter, painted oil filler cap, custom made cup holder, painted radiator retainers, polished slam panel, painted alternator, painted upper manifold, painted throttle body, painted header heat shield, painted relay bracket, painted loom brackets, painted diagnostics box bracket, painted wash fluid brackets, painted ABS brackets, painted airbox brackets, painted horns and brackets, painted throttle cable brackets, painted charcoal canister brackets and hard piping, painted wiper rods, painted engine hooks, painted clutch line bracket, Jass offset license plate bracket, offset square plate, 1lt foam fire extinguisher on custom bracket and custom Velcro retaining strap, POR15 rust proofed to within an inch of it's life, cavity waxed and fully seam sealed
 
UKDM 2001 mk2.5 - Current mods- SMD interior light, SMD number plate lights, Corbeau Sprint (yes it fits!), modified mk2.5 door card, Skidnation seat brackets, Corba 1046 remote central locking unit, Driftworks basics 350mm leather steering wheel, NRG short hub, NRG 2.5 quick release hub, 8" weighted gear knob, factory electric wing mirrors, factory electric aerial, Kage 4" exhaust with additional powerflow silencer, foam fire extinguisher, custom fire extinguisher mounting bracket, painted cam cover, painted oil filer cap, 15" Advan SA3Rs, Nankang NS-2R 180tw, offset plate bracket, RGB footwell lighting, sun strip, painted calipers and carriers, painted headlight inserts, softtop delete, brake fluid reservoir sock, GCR3 roll bar in custom gloss black, Corbeau Ultima Pro 2006SSU 6 point harness, push button bumper quick release pins, twin port oil catch can, engine bay respray, fully POR15 rust proofed chassis, full chassis seam seal, custom permanent hardtop side mounts, Jass permanent hardtop front mounts, M-tuned large rear rotor spacers with corresponding 276mm SVT brake discs, Freakyparts larger front rotor spacers with corresponding 11" Corado G60 front rotors, HEL braided brake lines, Byba Kits GV style front lip, SVT under chassis bracing, painted radiator brackets, 
mazdaspeed seat belt pads, charcoal canister delete, large Mazdaspeed side skirts, short shifter, 60mm alloy radiator, 3" brake ducts, upper strut brace with MC brace.
 
2004 Celica T Sport - Current mods- Meister Zeta Pro coilovers, Forged Wilwood dynalite front calipers, Yellow stuff brake pads up front, Drimpled and slotted discs, Braided brake lines, TRD stubby aerial, Short shift kit, 17" alloys powdercoated in metallic granite, TRD centre caps, Invidia exhaust, Cusco brake master cylinder brace, SMD side light bulbs, butterfly valve delete, Aux to CD converter, 8" gear knob, sun strip, interior SMD bulb, remote damper adjusters

 
Sold- UKDM 1992 1.6 Mk1 SE - Current mods- Yokohama A048 semi slicks, 15" Lorber 7JJ deep dish alloys, Tein street springs on OEM dampers, IL Motorsport catback exhaust, IL Motorsport decat, K&N greenstuff filter, OMP 330mm racing wheel, TR Lane half cage, TR Lane harness bar, Elise bucket seats, Sparco 4 point harness, Ebay special JDMyo! gear knob, GV lip, Vindii ducktail
 
 


#388 B_hawk111

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Posted 04 June 2020 - 11:30 AM

Bit more done today!

Old clutch out!

49953438161_ae23aacd97_c.jpg20200530_114328 by ben hawkes, on Flickr


So what I'm hearing is you are well practiced, want to help me do mine on the track car? it's a 50k mile super clean car lol

Mate, it is my most hated job 😂

My only advice is to just remove everything! The more shit you unbolt the easier it is to get the gearbox off and on!
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#389 Shadowraven

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Posted 04 June 2020 - 03:13 PM

Lol. Yeh, I've all the SVT bracing as well, fun times. 


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UKDM 1998 1.8 Mk2 Sport - Current mods-  Custom 6 point chassis mounted front splitter and sideskirt extensions, battery cut off switch, OEM 'small skirts' and lip, HEL braided brake lines, OEM front upper strut brace with MC brace and mazdaspeed sticker, custom made 2" high flow catback exhaust, Japspeed 4-1 exhaust manifold, Lorber 15" alloys in fiat 750 maroon volcano, uniroyal rainsport2s, Ebay special JDMyo! gear knob, tinted indicators, colour coded reflectors, black headlight inserts, LED sidelights, SMD number plate bulbs, dimpled and grooved mtec brake discs, mintex brake pads, de-tango'd headlights, amber bulbs, RGB footwell lights, SMD interior light, Deltastyling spoiler, foamectomy seats, mazdaspeed seat belt pads, ring ultimax headlight bulbs, IL Motorsport style bar in custom paint, ford fan washer jets, Skidnation coolant reroute with Kia thermostat housing, Gates 22436 radiator hose with hose bracket, 82/85 degree twin valve thermostat, D1 spec engine bay dress bolts, stainless steel bolts throughout engine bay, EGR blanking kit, painted brake calipers, painted tow hooks front and rear, wrinkle painted cam cover, de-greened dials with white SMDs, red needles, painted cigarette lighter, painted oil filler cap, custom made cup holder, painted radiator retainers, polished slam panel, painted alternator, painted upper manifold, painted throttle body, painted header heat shield, painted relay bracket, painted loom brackets, painted diagnostics box bracket, painted wash fluid brackets, painted ABS brackets, painted airbox brackets, painted horns and brackets, painted throttle cable brackets, painted charcoal canister brackets and hard piping, painted wiper rods, painted engine hooks, painted clutch line bracket, Jass offset license plate bracket, offset square plate, 1lt foam fire extinguisher on custom bracket and custom Velcro retaining strap, POR15 rust proofed to within an inch of it's life, cavity waxed and fully seam sealed
 
UKDM 2001 mk2.5 - Current mods- SMD interior light, SMD number plate lights, Corbeau Sprint (yes it fits!), modified mk2.5 door card, Skidnation seat brackets, Corba 1046 remote central locking unit, Driftworks basics 350mm leather steering wheel, NRG short hub, NRG 2.5 quick release hub, 8" weighted gear knob, factory electric wing mirrors, factory electric aerial, Kage 4" exhaust with additional powerflow silencer, foam fire extinguisher, custom fire extinguisher mounting bracket, painted cam cover, painted oil filer cap, 15" Advan SA3Rs, Nankang NS-2R 180tw, offset plate bracket, RGB footwell lighting, sun strip, painted calipers and carriers, painted headlight inserts, softtop delete, brake fluid reservoir sock, GCR3 roll bar in custom gloss black, Corbeau Ultima Pro 2006SSU 6 point harness, push button bumper quick release pins, twin port oil catch can, engine bay respray, fully POR15 rust proofed chassis, full chassis seam seal, custom permanent hardtop side mounts, Jass permanent hardtop front mounts, M-tuned large rear rotor spacers with corresponding 276mm SVT brake discs, Freakyparts larger front rotor spacers with corresponding 11" Corado G60 front rotors, HEL braided brake lines, Byba Kits GV style front lip, SVT under chassis bracing, painted radiator brackets, 
mazdaspeed seat belt pads, charcoal canister delete, large Mazdaspeed side skirts, short shifter, 60mm alloy radiator, 3" brake ducts, upper strut brace with MC brace.
 
2004 Celica T Sport - Current mods- Meister Zeta Pro coilovers, Forged Wilwood dynalite front calipers, Yellow stuff brake pads up front, Drimpled and slotted discs, Braided brake lines, TRD stubby aerial, Short shift kit, 17" alloys powdercoated in metallic granite, TRD centre caps, Invidia exhaust, Cusco brake master cylinder brace, SMD side light bulbs, butterfly valve delete, Aux to CD converter, 8" gear knob, sun strip, interior SMD bulb, remote damper adjusters

 
Sold- UKDM 1992 1.6 Mk1 SE - Current mods- Yokohama A048 semi slicks, 15" Lorber 7JJ deep dish alloys, Tein street springs on OEM dampers, IL Motorsport catback exhaust, IL Motorsport decat, K&N greenstuff filter, OMP 330mm racing wheel, TR Lane half cage, TR Lane harness bar, Elise bucket seats, Sparco 4 point harness, Ebay special JDMyo! gear knob, GV lip, Vindii ducktail
 
 


#390 B_hawk111

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Posted 04 June 2020 - 09:36 PM

Manifold is back on!

49971514661_2a22d32983_c.jpg20200604_105053 by ben hawkes, on Flickr

49971777162_cacf9b90a0_c.jpg20200604_164627 by ben hawkes, on Flickr

Looks really cool, but as long as it functions and keeps the temps down that's all that really matters!

I also finished ripping out the abs! Ran a new alarm wire into the boot, seemed pointless having the bonnet alarmed and the boot not, especially as you could just open the boot and unplug the battery!!

And lastly I spent a few hours trying to work out how to get the vehicle speed sensor working through the me221.

Main reason is to disable launch control when moving, so it removes the need to have clutch switches and stuff!

After a lot of reading, I finally worked out how to wire it all in and get it working using the Reed switch on the clocks that was used for cruise control.

First weird thing I found was that I already had the wire on the clocks loom!

Multi metered that and it was connected down to the ecu!

But more multi metering showed it all worked as expected, but my research said I needed to feed a 5v pull up into that wire otherwise it won't work.

I then decided to plug the ecu into the laptop and see if it reads anything.

Turns out after all that and 3 years of having the ecu fitted to my car, the VSS works perfectly already!

Guess that's what I get for having this odd crossover year car and not actually checking!

Ah well, interior can go back together tomorrow, then run the car up and check the new throttle body, cabling I've changed, and bleed the coolant! Then onto some fun bits!
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#391 B_hawk111

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Posted 05 June 2020 - 09:12 PM

Good amount more done today!

Bled the coolant, it ran up to temp nicely, one small leak from a badly seated pipe so sorted that and away it went!

Let it run up till the primary fan kicked in and it dis its job nicely pulling the temps back down.

Then as a test I unplugged the primary and once it got a few degrees hotter the secondsry fan kicked in and again pulled the temps right down.

Then rewired my launch control switch, put the interior back together, bled the clutch and re bled and checked the brakes, one small leak again, fixed by just tweaking the fitting a bit tighter!

And finally fitted a new wideband sensor and put the TDR manifold blanket back on!


Oh and sprayed the hardtop with filler primer!

Tomorrow is going to be colour and clear on the inside, then hopefully early next week colour and clear on the outside!

49975130112_ea05d5864a_c.jpg20200605_185919 by ben hawkes, on Flickr

49974347128_f9a12beb1c_c.jpg20200605_185922 by ben hawkes, on Flickr

49975129852_64b2928516_c.jpg20200605_190416 by ben hawkes, on Flickr

49974347038_7c4f56a40a_c.jpg20200605_190426 by ben hawkes, on Flickr
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#392 carl s

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Posted 05 June 2020 - 09:40 PM

Interesting that you have two fans, I have my a/c fan still fitted (despite the a/c not being there any more) I was wondering if it was worth wiring it in and what to use to trigger it.  I do have an ME221 fitted...


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mk1 1991 Eunos with RS NB drivetrain: https://www.mx5nutz....howtopic=322586

ex - mk3 2006 2.0 sport

ex - mk2 1999 1.8is JRSC


#393 B_hawk111

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Posted 05 June 2020 - 09:48 PM

Interesting that you have two fans, I have my a/c fan still fitted (despite the a/c not being there any more) I was wondering if it was worth wiring it in and what to use to trigger it. I do have an ME221 fitted...


I had problems with my fan last year and it lead to the car overheating a couple of times!

I replaced the main fan and just thought I might aswell just mount up the old one as a backup!

If your old fan is still wired in, you should be able to trigger it from the me221!
If not its quite easy to wire up.

The me221 switches ground, so just use it to run a relay to power the fan.
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#394 B_hawk111

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Posted 06 June 2020 - 09:47 PM

Today I was going to spray colour and clear on the inside of the hardtop!

I changed my mind though, and decided to spray the inside with filler primer first too! Hopefully it will get a good finish all over then!

49977852878_9434759412_c.jpg20200606_125145 by ben hawkes, on Flickr

My new spring turned up from forge too so I got the dump valve rebuilt and ready to go!

49978633067_bb42463de9_c.jpg20200606_133213 by ben hawkes, on Flickr

49978372161_a764635196_c.jpg20200606_133530 by ben hawkes, on Flickr

I also started to prepare the intercooler pipes for modifying and paint!

The dei gold heat reflective tape is a real pain to get off! It's taken a lot of effort to get the glue off! But it's almost there! Just news my 25mm pipe to arrive to weld on!

49977852628_8c2e33e4cc_c.jpg20200606_133702 by ben hawkes, on Flickr
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#395 B_hawk111

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Posted 07 June 2020 - 09:54 PM

Took a dry 20 minutes to start sorting the charger out, removed all the complicated pipework which was once needed to avoid the abs system!

Before!

49982426847_223252cf83_c.jpg20200607_121021 by ben hawkes, on Flickr

49982170571_90125fe45a_c.jpg20200607_121025 by ben hawkes, on Flickr

After!

49981646813_14d1e46ec4_c.jpg20200607_123040 by ben hawkes, on Flickr

49982426502_0427291e12_c.jpg20200607_123043 by ben hawkes, on Flickr

So much neater and cleaner! I've ordered the new couplers for the bypass valve and for the dump valve! Still just need to weld on the outlet for the dump valve but the pipes stuck with snail mail!

Then while it rained today I got the inside of the hardtop painted!

I mixed some of the black I plan to use for the outside with some purple I had from a bike frame! Made a really cool almost red tinged black!

49982426167_0f7979fb2b_c.jpg20200607_180141 by ben hawkes, on Flickr

49982169796_4e9c7b40a9_c.jpg20200607_180154 by ben hawkes, on Flickr

49981646293_8d1e53a035_c.jpg20200607_191810 by ben hawkes, on Flickr

Need to leave that a few days now to harden before I flip it over and paint the outside! Quite pleased with the finish though! Much better then scuffed and chipped satin black!
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#396 B_hawk111

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Posted 08 June 2020 - 09:56 PM

Got the car back in its wheels today finally! And started working on intercooler pipework and re fitting the supercharger!

The hot side intercooler pipe was always a bit of a pain as the silicone 45° bend was too small for the intercooler pipe, but also rubbed on the power steering pump!

So I decided to weld in a hard 45° bend and just use a straight reducer to fit it!

49985339598_d182c7f520_c.jpg20200608_153434 by ben hawkes, on Flickr

49985339463_aa16138d0a_c.jpg20200608_153647 by ben hawkes, on Flickr

49985339543_6fa5a050c3_c.jpg20200608_154520 by ben hawkes, on Flickr

Works loads better, so that was welded up and ground flat, very happy with it!

49985856391_f450e2ef7b_c.jpg20200608_183404 by ben hawkes, on Flickr

Then after waiting all day for it to arrive, I finally could weld in the outlet for the dump valve!

49985856146_43d3bea8b3_c.jpg20200608_201917 by ben hawkes, on Flickr

49985856086_ba8fa0cbab_c.jpg20200608_202459 by ben hawkes, on Flickr

So just waiting on a few bits of silicone to join the bypass up, and for the dump valve and it should be good for a test drive!

Also today I shortened the theottle cable, and ran the vaccume hose for the bypass valve. And also ran the pipe back in for the breather.

Almost ready to take off for mapping again!
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#397 B_hawk111

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Posted 09 June 2020 - 08:31 PM

Decided I couldn't wait for the proper pipes to arrive, so bodged some bits together and gave it all a go!

Pipes and dump valve look good!
Theottle is nice and light still which is good!

Dump valve seems to opperate properly!
Big piston opens at idle but the little one stays shut to keep it all sealed, then as boost builds big piston shuts.

I tried to rev it up enough to build enough boost to try and make it vent properly but it blew my makeshift pipe off 😂

Shall have to wait for proper pipes before I can give it the proper sound test

49989196131_e4b35c6d19_c.jpg20200609_161326 by ben hawkes, on Flickr

Oh and this is the box of stuff that has so far been removed from my car in place of the new simple non abs system! And this doesn't include the actual abs components!!

49988677468_f411f00ac8_c.jpg20200609_163444 by ben hawkes, on Flickr
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#398 B_hawk111

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Posted 10 June 2020 - 08:19 AM

Short video on my Instagram before the pipe blew off 😂

https://www.instagra...d=17r8h3x2nq6ek
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#399 B_hawk111

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Posted 10 June 2020 - 09:38 PM

Gave the car a well deserved and much needed clean this morning!

49992939931_b7646693b5_c.jpg20200610_121951 by Ben Hawkes, on Flickr

And then I had an unexpectedly early delivery of all the silicone hoses and joiners I needed from ASH!

So that all went in and together!

49992418243_8035218978_c.jpg20200610_152340 by Ben Hawkes, on Flickr

49992939711_776116175d_c.jpg20200610_152352 by Ben Hawkes, on Flickr

I've changed the coolant overflow line now so it turns 90° and runs around behind the radiator instead of directly under the intercooler pipe!

Works much better but I had to cut down the outlet on the radiator as it was still too long, and in doing so I think I unscrewed it ever so slightly so it started leaking.
Then it started raining so I only got a quick run up and down the road to check things are working, which they are!

The new bofi clutch feels great, literally no different in terms of bite or feel to the exceedy one, but can apparently hold 400bhp!

And then more unexpected delivery's arrived!

49993187612_1f6471c1ac_c.jpg20200610_201208 by Ben Hawkes, on Flickr

Finally managed to find where to buy jetex racing air filters! So got myself an identical (but much newer and less squashed) air filter!

49992417778_08dab1635b_c.jpg20200610_201237 by Ben Hawkes, on Flickr

And some Fresh plugs!

49993187532_d7a27b222c_c.jpg20200610_201249 by Ben Hawkes, on Flickr

And some fresh rubbers for the hardtop!

Speaking of which!

49993188012_e1d651b246_c.jpg20200610_185735 by Ben Hawkes, on Flickr

49993187912_e1d9aa1055_c.jpg20200610_185740 by Ben Hawkes, on Flickr

That is the outside all flat back and ready for some colour and clear!

Sanding makes such a mess and I hate it, but hopefully I've done a good enough job to get a decent finish on it!

Shall find out tomorrow!
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#400 carl s

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Posted 10 June 2020 - 10:38 PM

Great progress, I crawled around in the rain under my car today, nothing as successful as you! with that intake have you ever considered taking the air from the windscreen bulkhead? just a quick 90 degree bend and you've got a cold air randell-style intake to the supercharger.


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mk1 1991 Eunos with RS NB drivetrain: https://www.mx5nutz....howtopic=322586

ex - mk3 2006 2.0 sport

ex - mk2 1999 1.8is JRSC





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