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General => General discussion => Topic started by: Peej1981 on 10 January 2011, 21:53
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Well it has come to that time again were i need some advice. Basically i had decided with the help of a LowLifeDubber to recon/rebuild my supercharger. Now we are both know our way around cars and toolboxes so not really worried too much about it. We have gone through a lot of information on how to do this work and read step by step instruction on how it is done however what i really wanted to know is what actually has to be done to make the charger into a stage 4? How much needs to be ported from the inlet? I have read what G works say they do and what Jabba say to but they dont really go into any detail (which is obvious really why they dont :angry:) so this is why i am asking you lot on here, has anyone done this before and have pics they could send me or does anyone know what is needed to get it to stage 4?
I am not planning on doing this work until march time as want to try and gather as much info as possible and watch any vids i need to, the last thing i want to do is just jump in there ripping it apart and fuc*ing it up as cant really afford to buy a new one at £900.
A lot of you might be thinking why dont i just take it down to G works or Jabba sport but there are 2 main reasons, 1. I cant really afford to have them do a stage 4 on it 2. I am a trainee mechanic and as such want to learn how it is done as this will save me money in the long run but also may end up making me money too :grin: :grin:
So really would like any info you guys have, links for vids, ideas, suggestions and if anyone knows where to buy the parts to do this job for a good price then let me know. Or are we actually we stupid to undertake this task :laugh: :laugh:
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WORK CLEAN VERY VERY VERY CLEAN
clean the outside of the charger very well before cracking it open, when it's open don't leave it on the bench if your not working on it put it in a clean platic bag and seal it.
meticously clean all the parts as you remove them ( my personal choice for this type of job is ether an old spray gun loaded with thinners or to blast with thinners from a blasting / washing gun )
with G -laders there is no "f**k it" or "that'll do" allowed. do it right and it'll be spot on bodge anything and it'll develop and go bang
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Are the seals etc still avilable from VW :undecided:
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Thanks for the advice Danny, i was already aware of what you have said through reading through alot of sites i have found. I already have some spray guns and thinners from when i did alloy refurbs so thats all sorted. I was thinking though that want sort of paint do they use on the outside when they spray them back up, as it has to be heat resistance, durable as when i read some sites about it all they say is that it is some special formulated paint?
Like i have said that i am not just going to jump in there and this is why i need to gather as much info as possible before me and LowLifeDubber take this task on.
Are the seals etc still avilable from VW :undecided:
Not sure really :sad: Still looking into this, i have emailed Jabba to see if they sell a rebuild kit that includes all the parts they would normally use themselves?
So does anyone know what the measurments are for a stage 4 charger? We have all the equipment to carry this job out so i thought as i have the charger off i would look at converting it to stage 4.
My search carrys on :grin:
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The G scrolls inside cannot be made larger as such so it would be interesting to find out what they do to make a stage 4 charger.
They are a simple unit really, make sure you replace the small belt that drives both parts,just been looking at Jabbasport, they do rebuild kits with and without bearings, I would say you would be better to strip it and see if you have any play in the bearings 1st.
(http://i125.photobucket.com/albums/p51/jmfangio5/G6020Rebuild20Kit20650w.jpg)
Reference paint, a heat resistance paint will be fine.
One last point is that the rebuild kit is £229.56, from vw I would guess it would cost more, stage 4 charger rebuild is £463 is it really worth the saving, they say 4 days turnaround.
Performance upgrade including service
* Completely dismantle, clean & inspect all components
* Casings Glass Bead blasted for a professional finish
* Port/Flow G-Lader Outlet
* Modify casing chambers to aid cooling to diffuser counter shaft bearing
* Port diffuser / scroll
* Replacement of bearings (steel cage)
* Replace oil seals with upgrade high pressure oil seals
* Re-new APEX seals
* Re-new outer shaft steel ring
* Upgrade to wide timing belt
* Balanced
* Application of special coating to enhance boost
* Re-assembly of G-Lader
* Pressure test
* Certificate of G-Lader rebuild with serial number
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The G scrolls inside cannot be made larger as such so it would be interesting to find out what they do to make a stage 4 charger.
They are a simple unit really, make sure you replace the small belt that drives both parts,just been looking at Jabbasport, they do rebuild kits with and without bearings, I would say you would be better to strip it and see if you have any play in the bearings 1st.
(http://i125.photobucket.com/albums/p51/jmfangio5/G6020Rebuild20Kit20650w.jpg)
Reference paint, a heat resistance paint will be fine.
One last point is that the rebuild kit is £229.56, stage 4 charger rebuild is £463 is it really worth the saving, they say 4 days turnaround.
Performance upgrade including service
* Completely dismantle, clean & inspect all components
* Casings Glass Bead blasted for a professional finish
* Port/Flow G-Lader Outlet
* Modify casing chambers to aid cooling to diffuser counter shaft bearing
* Port diffuser / scroll
* Replacement of bearings (steel cage)
* Replace oil seals with upgrade high pressure oil seals
* Re-new APEX seals
* Re-new outer shaft steel ring
* Upgrade to wide timing belt
* Balanced
* Application of special coating to enhance boost
* Re-assembly of G-Lader
* Pressure test
* Certificate of G-Lader rebuild with serial number
mmm i can see what you are saying but like i said i would really like to learn how to do it myself, If i could get hold of the money for them to do it do you think they would allow me to watch how they do it, if i explain the i am studening to be a mechanic? I was thinking of buying the bearings anyway as want to replace everything, even if my bearings are ok then i suppose i can clean them up and have them as spares?
I suppose the other issue would be that i wouldnt have a certificate to prove the rebuild for if i ever sell the car, it might put people off if i say that i have rebuilt it myself?
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I suppose the other issue would be that i wouldnt have a certificate to prove the rebuild for if i ever sell the car, it might put people off if i say that i have rebuilt it myself?
That is a good point and yes I can see it putting people off.
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Not sure this is a good idea DIY?
How much money will you save?
2 problems, one is resale as already stated.
Second, much bigger problem, if anything goes wrong it could mean new engine time :sick:
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Not sure this is a good idea DIY?
How much money will you save?
2 problems, one is resale as already stated.
Second, much bigger problem, if anything goes wrong it could mean new engine time :sick:
Yeah didnt really think about that side of it, I suppose the best thing to do is email jabba and ask them if they would let me stand in to watch what they d to rebuid the charger and then have it at least done by them, this way i get a certificate and the charger should last me 25k before next rebuild in which case i might be able to do it myself then or might have sold the car, either way it is probably best to learn from the experts first then try yourself? This will also mean i will be left skint but is suppose thats the price to pay when you run a G60 :rolleyes: :rolleyes:
What ever happens i do really want to learn how to rebuild the charger and i will see what jabba say :smiley:
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It,really doesnt look that hard at all mate.The only downside i can see is the resale issue,but we would document it anyway.You also have the best of both worlds as im a qualified mechanic and also a qualified mechanical engineer so that will help us out. :grin:
If you do decide to take it to Jabbasport you can still come over when i rip mine to bits. :cool:
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This is going to be interesting indeed!
:wink:
(http://i202.photobucket.com/albums/aa51/Clipperjay/Rallye4sale/CH2.jpg)
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Is this any help? http://www.matey-matey.com/g60-rebuild-article.shtml (http://www.matey-matey.com/g60-rebuild-article.shtml)
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if i made my living reconditioning superchargers i definately would let a mechanic watch how it is done!
i have no doubt that you and lowlifedubber are capable of reconditioning the unit but modifying it i would leave to the experts. they will know what to take from where, what to polish, what to port.
if they do something wrong and the charger explodes i am fairly sure legally and morrally they will sort it.
if you blow your engine then its a phone call to me for my spare lump and you will be rolling on a k-jet 8 valve with 210,000 mikes!
think of the consequences of your tightness!
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We have that link thanks.Proper good read that is!
I don't have any quarms about rebuilding it but ive said to PJ id rather not tackle the mods for fear of flucking it up! :grin:
I bet companies keep the info close to their chest too.I spent an hour last night searching for specs of a stage4 but no joy with dimensions etc.
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mmm some stuff to really think about here, i really would like a stage 4 and i would also like the fact that it would certified however myself and lowlifedubber would really like to rebuild it for personal knowledge. What if i contacted jabba and see if they would allow both of us to go down and watch how they do the rebuild then that would give us good knowledge for yours?????
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The funny thing about chargers you need to look at one in pieces before you understand how it comes together! I would be inspecting sealing strips and scroll conditions as the strips wear down so does the scroll. You find glazing on the inner casing where the scroll itself has wore against the inner casing. At this point the seal strips could fall out of the seats as there is no seat left.
There is no real effort to change out all seals and strips, but porting is another story as discussed already!
Look at my charger pics its a RS4 spec or the limit of output as I have only three support prongs on the outlet.
To get this ported to this standard its about 700 Eurs from Germany check there Site SLS.
I might take my spare charger out and post pictures if you want Kai?
Jay
I'm sure we can get rebuild kits alot cheaper for a stock charger :wink:
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i have a jabba R1 ported 'charger in pieces (damaged scroll) i could be persuaded to loan it to you so you can see where they take the material from.
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Would the dudes at this new job be able to help you? If so, hold tight :smiley:
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Pay the money let jabba do it. its neh worth the hassle. I've blown the arse out of one of my chargers before and yes, it wrecked the engine too....
so for resale and peace of mind.... let the pros do it!
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Would the dudes at this new job be able to help you? If so, hold tight :smiley:
Not really sure as didnt really ask them, i start in Feb so will ask them. Jabba still havnt got back to me so i think i will have to phone them tomorrow and see what they say.
On a more fun note, had a enjoyable race against a Civic Type R today on the way home from college, what was even better was the fact i manage to get past him and started to pull away from him on the strights, he tried t over take me but couldnt and wasted him round corners :grin: :grin: :grin:
He didnt look too impressed when he pulled up at the petrol station and i was already there halfway through filling mine up :grin:
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In case you didn't know, this lot are well worth a look:
http://www.bar-tek-tuning.de/