Rtech Supercharger system for HP500EFI
 

The design is completed. Here are a few screen grabs of the solid model. Thanks to Nordic Heat for converting my 2D drawings.

If you are familiar with the Vortech system for this engine, we occupy the same real estate but squeeze in a bigger, better flowing intercooler. We will sell this as an upgrade to Procharger systems or as part of a complete system using the Vortech supercharger.

The Supercooler mounts on the throttle body using longer bolts. Stock throttle linkage is retained. Weight is also supported from the stbd cylinder head.

Looking into the upper part of the plenum through the compressor discharge tube. You can see the turning vane at the far end.

This picture of the Vortech intercooler plumbing may help explain what we have done.

This drawing shows how the air from the supercharger enters a gradually widening upper plenum without running through any small diameter plumbing.

The air then passes through the top part of the intercooler core. Passing through the core takes the turbulence out of the air flow. This effect, plus the large cross-sectional area of the turn, and the turning vane itself, all combine to reduce pressure losses in the 180 degree turn.

Partially cooled air then passes through the bottom part of the core. Since cold water enters the bottom part of the core from the stern, makes a 180 degree turn and exits from the top part of the core, this is a true countercurrent design which maximizes heat removal.

Cool air then enters the lower plenum. The throttle body draws off this lower plenum without the pressure losses of running through small diameter plumbing.

The Supercooler will be tested as part of a complete Vortech system installation in May. Of course, results will be reported here first.

A fellow OSO member who already has the Procharger system installed has volunteered to test the Supercooler back to back against the Procharger intercooler. The Procharger system requires the intercooler to be mounted below and beside the engine. He currently has 5 @ 90 degree elbows in small diameter tubing, so we expect to greatly reduce pressure losses with the Supercooler.

We expect to be ready to deliver product this summer. We are ready to go to casting and maching now, and the intercoolers are being custom made for us by the same company that makes Vortech's intercoolers.

We are aiming this product at engine builders that want to produce 800-900 HP from 502 - 540 CID engines using the Mercury EFI system with large injectors and modified ECMs.

Details of previous supercooler tests can be found on our website. Click on our OSO banner or go to www.rtechperformance.com.

I look forward to comments from all OSO boostheads!:D

After getting a primer of how it works, you'll be dominating the market once people start realizing what it is.

Great job.

It looks fantastic Tom!

It will be fun testing this new design. Keep me in the loop.

Kurt :cool:

Who does your computer recal?

With that manifold system being increased, won't it create a larger area of compressed air, with throttle response suffering during deaceleration?

ECMs will be done by the same people that do Vortech's; i.e. Arizona Speed and Marine. In the case of the Procharger test the ECM will be done by the same guy that did it in the first place, Mark at Precision Marine.

Throttle response will not change since the position of the throttle body has not changed. Throttle bodies are huge restrictions to air flow when they close. Air always seeks the eaisest path which is back out the compressor. That's why a bypass valve is recommended at higher boost levels.

Ausome job!

I walked into the shop that is doing the first installation of this system yesterday and they had a little surprise for me. A 35 Fountain with the 502 MPIs already out and on dollies. They are putting complete XR transom assemblies and drives on the boat and the owner wants Rtech supercharger systems on the engines.

So now I'm working like a madman to finish the design of the supercooler for that engine. Nothing like a deadline to make things happen!:rolleyes:

I will post drawings ASAP.

Tom

The design was easy compared to the HP500 EFI because there isn't a headroom issue on the 35 Fountain. This design won't fit if your hatch is within 6 inches of the stock upper plenum of the intake manifold. I did it this way because it is the cleanest air flow and counter current water flow. Simple layout means a casting is not necessary; the same box and plate fabrication as the carb system works well.

Solid model shows how the bottom plate bolts on using the throttle body studs.

The box sideband and plenum divider are shown; the intercooler and the lid are not shown.

This is the blower's view of the transition into the supercooler. Connecting hose goes from 3.5" to 4". The transition takes the 4" diameter to 4.5" X 10", which is the area of the upper core.

Gee Tom, I suppose my free demo model is in the mail :)

Yeah, it's in the mail...along with the free XR drive to handle the power!:rolleyes: How's the project going? Heads show up yet? Get that engine back in the boat, I want to measure something!:D

WHAAAAA, ya don't think my BlackHawk can handle 800hp? ;)

Heads are due in today. Machine shop has been modifying them a little bit :)
Hopefully spend this weekend assembling engine and installing next weekend.

This is the general arrangement of the twin setup in the 35 Fountain engine compartment.