Long Shot Supercharger Rebuild Advice

[Peej1981]

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 ) 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 

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 

[danny_p]

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   

[Wayne]

Are the seals etc still avilable from VW 

[Peej1981]

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 

Not sure really  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 

[Wayne]

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.



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

[Peej1981]

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.



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?

[Wayne]

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.

[AudiA8Quattro]

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 

[Peej1981]

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 

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 

What ever happens i do really want to learn how to rebuild the charger and i will see what jabba say 

[LowlifeDubber]

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.

If you do decide to take it to Jabbasport you can still come over when i rip mine to bits.