Procharger HO Air/Air FMIC mated with a Paxton Novi 1500

Ok, now I am not sure if this is a first, but I sure have not seen it being done before, so I was kinda in some unknown waters here!!! lol After much debate over what to do about my extremely high intake temps, I decided to go to an air/air FMIC set up. When I really started to look at systems, whether making my own hybrid, or doing something else, I noticed how similar the Procharger HO system was to my Paxton Novi 1500. Low an behold I am watching Speed one night and see an install of a Procharger on a Challenger and thought, I bet this would work!!!

Well after some great help from the guys at Procharger and most importantly from Dave (Fixer), I made the leap!!! Now, not having an install manual, and not starting until about 8:00 pm last night, I ended up doing an all nighter and still have yet to sleep!!! lol Here are some basic shots of the process as best I could. Sorry for the crappy pics, I had to use my sons camera due to the fact my wife took the good camera with her out of town for the weekend!!! Yeah, I stayed up all night working on my car....... no poker, porn, or other fun..... just wrenching!!! lol

Here is what I started with. Very inefficient GSM designed water/air that saw intake temps routinely above 160.




First taking the nose off to reveal what has to go.....



This is what is going in!!!



No more dealing with water pumps and bulky tanks!!



Tear down and draining is progressing smoothly!!! Spilled A LOT of water doing this!! lol



Bye - Bye water stuff!!!



Fresh slate!!!



While I had things torn apart, I installed my new fan assembly!!! Go-Parts.com..... 95 bucks!! Unfortunately it turned out I have a bad relay for the low speed fan!!! argh!!!



First, radiator has to be dropped 2" in order for the inlet and outlet of the intercooler to have room above the radiator. Thanks Fixer for making the spacers for me!!! This also required me to relocate my meth pump because it is mounted to the radiator support. No biggie, I drained the washer bottle of all meth, unscrewed pump from support and remounted once support was dropped!



Intake plenum from intercooler to TB.... notice the convient location for my meth nozzle!! This is the IAT sensor hole, but I used it for the meth and left my sensor down at the filter. I switch things to monitor actual IAT's when tuning and doing comparisons.



Plenum from blower side to inlet of intercooler. Very tight fit to the belt/pulley!!



Intercooler installed. Again, with out instructions, and being a tad tired at around 3 in the AM..... I forgot to relocate the trans cooler to below the intercooler at first!!! Also, the brackets that come with the HO kit mount between the bumper and the frame. A tad bit of prying with a large screwdriver was needed to get enough room to sandwich the bracket inbetween. Also, the brackets then require some "massaging" (bending) to come away from laying flat on the inside of the bumper support, in order to line up with the intercooler mounting holes.



This was the part that was a bit of a guess at first. Low and behold, the connecting elbow from the intercooler to the blower was almost perfect fit!!! The biggest issue I am having right now is the junction of the black elbow and the blower. When I first measured the blower outlet, I saw 3". The black elbow actually is a touch bigger that the blower outlet. Actually, the elbow slides perfectly over the blower outlet and overlaps the outlet of the blower by about 1". I thought this would be cool, but the problem I discovered on the maiden drive was the inability to get the rubber coupler tight enough to cinch down on the blower outlet. First WOT and it blew off!!!



biggest obstacle I thought would be the BOV. I wanted to use the same one I had from before, but had to get "creative" on how to connect. I just cut off the mounting stub from the old GSM after cooler and used hight strength heater hose to connect to the stub coming off the blower side intercooler plenum.



Bumper back on and added a little high heat radiator paint to the tanks sections only to try and be a little stealthy. That, and the car is pretty much all black!! lol



Final product!!!



All in all, not too big a project. I'd give it an 8 on the wrench scale!!! Started at 8:00 pm on Friday night, and finished with the test drive at 6:30 am Sat. morning! Now, I am going to get some sleep, and then go out and do some logging of temps!!! I will update soon as to what kind of drops I see. I will say this, the car seems to have quite a bit more bite to it. Just ask some of my fellow FLXC members that witnessed the 30 mph rolling shredding of my vreds!!! dahahahahaha

 

Looks great! I am looking forward to seeing it in a couple weeks!

 

Great job Chris.

 

Holy crap, who thought Chris could turn a wrench? That looks great! and with pics too! It will be interesting to see the temp improvement.

 

brad - looking forward to seeing your beast as well!!!

ron - thanks buddy!!!

dave - you are a douche!!! just because you have all the manuals at your finger tips does not mean you turn wrenches!! lol as for the temps..... when i get home from the office...yes, i ended up in the office today..... and tomorrow...... i will try and do some loggin with the pred to see what kind of iat's i have now!!!

 

DAMN BRUDDA!!! Good for you man, good for you. Anxious to see how she performs now. Install looks KILLER. Not bad for a rookie, homeboy! Keep us posted (I know you will, ya whore)

 

that is wicked, love it man

 

That was a lot of work but it seems to be worth it. Nice job!

 

rookie...... lol...... just cuz the car looks pretty doesn't mean i never turned a wrench before..... remember who installed the s/c in the first place!! lol

thanks!!!

it was not too bad.... just tedious when you do it all by yourself! lol hopefully i will see the power that was being robbed by the hot air!! lol

 

You're gonna need a transmission soon......get ready......

 

I'm guessing it's going to be a lot (of power). 160 is hot. What are you hoping for, something like 120? more? less?

 

SHHHHHHHHHHHHHHHH!!!!!!!!

i am hoping for as close to ambient i can get. definately under 120......

 

Looks great man! Love the flames!!




As far as this....

Get a 3" to 4" silicone reducer and cut the metal elbow down so it's not fitting over the blower outlet....

 

thanks!!! the reducers would work, but the elbow is just right at three and the blower is just under three. all reducers i can find are in at least half inch increments and the difference i am dealing with is less. i did fix the issue today..... realized the band clamp i used on the blower was "bottomed" out and would not tighten anymore...... changed clamp and issue is solved.

 

Very nice Chris. You got any numbers yet?

 

Looks great Chris! Just out of curiosity, where is the blow off valve now?

 

Its in the picture of his first post..:bigwink:

 

Looking good my man... I might be in your rear view instead of the other way around:kiss: NOT!!!!!!!

 

Chris........

That is sweet!!!

Congrats!

 

thanks hal..... working on that today when i get done at the office...... yeah, got to work on a sunday!!!! and for "free"...... being salaried does have some down sides!! lol

look at one of the last pics...... the one where i reference what i thought would be an obstacle right above the pic showing the bov.....:whistle:

only time i am behind you is when......:whistle:

thanks albert!