BELOW ARE PARTS AND TOOLS REQUIRED FOR THE DIY INTERCOOLED SUPERCHARGER CONVERSION
When the list is finished, we will add a button to download a PDF version to save or print for reference during parts purchasing. (The system will ask for your contact information but will not require payment.)
The interim running total is approximately $1,935. Again, this is not yet a complete list—the silicone snorkels, T-bolt clamps, and aluminum joiner tubes will add another significant chunk.
Add $150~250 for a pre-pulled, serviceable used blower if you are not lucky enough to get one for $55 from national chain U-Pull-N-Pay.
Add $71 for a 90-amp CS121D alternator (from a late model Saturn), if you do not already run an alternator. (A generator can be used, but their bearings may not hold up well to the increased side-load from the serpentine belt.) The CS121D comes with a 5-rib serpentine pulley installed, and just needs ‘clocking,’ which can easily be done without dismantling or damaging the unit.
- Parts -
To order any of the below Creative Spridgets parts or free downloadable diagrams, click here or navigate to the 'purchase' page using the links at the top of the page.
Creative Spridgets M45 manifold - $225;
OEM Mercedes supercharger manifold gasket no. A 111 098 03 80 - (Partsgeek.com $8.22);
Fasteners for M45 manifold: M8-1.25x45mm socket cap screws - Crown Bolt 219-100 (6 pcs) (Home Depot - $5.52); M8 stainless flat washer – Everbilt 411-450 (6 pcs) (Home Depot - $1.10);
Creative Spridgets 5-rib serpentine belt crankshaft pulley - $175 (requires SKF speedi-sleeve no. 99156, Amazon.com - $26.78, CARiD.com, $20.33);
Smoothflow A-series 5-rib serpentine belt water pump pulley - $99;
Smoothflow M45 modular supercharger pulley system - $90;
Creative Spridgets SU HIF44 ram pipe & snorkel adapter - $61.50 (includes hardware);
Creative Spridgets supercharger bypass valve adapter - $27.50 (includes hardware);
(If running down-flow radiator) Creative Spridgets thermostat housing adapter - $85;
Eaton M45 (45 C.I.D.) supercharger, model no. 207018, from 1999-03 Mercedes Benz SLK230 Kompressor coupe and 1999-00 Mercedes Benz C230 models without electronic clutch - $54.50 U Pull-N-Pay (including core charge & environmental fees) (add $150~$250 for pre-pulled unit);
Creative Spridgets M45 supercharger mounts - fabricate with free downloadable diagrams. Steel cost is $25~$40 depending on source. You will need:
Front mount: Cold finish mild steel rectangle – 6” x .1875” x 12” length; Hot rolled mild steel angle iron – 2” x .1875” x 10” length; Cold finish mild steel rectangle – 1” x .125” x 12” length;
Rear mount: Cold finish mild steel rectangle – 3” x .1875” x 6.5” length; Hot rolled mild steel angle iron – 1.5” x .1875” x 5” length; Hot rolled mild steel angle iron – 2” x .1875” x 12” length;
2002 Mini Cooper S supercharger bypass valve - $94.90 Europarts.com or pennies on the dollar at wrecking yards;
Gates radiator hose no. 21972 for bypass circuit - $14.98;
Intercooler from 1999 Audi A4 Turbo 1.8L, Spectra no. 4401-1110 – $110.79 Rockauto.com, various sources or pennies on the dollar at wrecking yards;
Rebuilt HIF44 carb - $346 A-Series Spares (including shipping from UK), or Mini Mania for $369, or Moss for 699.99;
*Note: you can also contact Joe Curto, Inc. by clicking here. Joe can supply any parts you may need to equip your HIF44—such as needles, springs, or throttle spindle seals. He may have a reconditioned HIF44 on-hand for sale, as well.
Minispares C-AHT770 manifold - $66.81 including shipping from UK;
Idler pulley – Dayco # 89535 54mm dia., 30mm wide Rockauto.com, various sources - $20.79;
Combo spacer & idler bushing - .375” Id. x .590” shoulder - Lawnmowerpartsworld.com part # 10969 - $1.60;
Belt tensioner – Dayco # 89258 Rockauto.com, various sources - $16;
5-rib serpentine belt - Dayco # 5050570 (alternate # 5PK1450, replacement # 570K5) Amazon, various sources - $7.81;
Fuel pressure regulator, such as Aeromotive 13301 Universal Bypass Regulator - Summit Racing - $131.95;
Fuel pressure gauge, such as Auto Meter 2179 – 60 psi - Amazon - $34.29;
High-pressure fuel pump, such as Walbro GSL-392 In-Line Fuel Pump w/fittings, hardware - eBay $46.99;
Fuel pump relay, 30 amp universal w/pigtail – Amazon, eBay - $3.99;
EFI-spec fuel filter, such as (inline) ACDelco GF652 Professional Fuel Filter, $8.02 - Amazon, or 1996-98 Subaru Legacy (upright style) Fram G7367 - Amazon - $19.62 or Autozone/Duralast FF739DL - $9.99;
If using upright filter, 1996-98 Subaru Legacy fuel filter bracket - U-Pull-And-Pay, various wrecking yards - $5.00;
Surge tank, such as Rotary works RW-FST02 - Rotary-works.com – $89.00;
5/16” stainless fuel line, 20’ coil (Jegs - $48), or nickel/copper line, 25’ coil (Amazon - $48)
[to be continued…]
- Special Tools -
In addition to a good set of mechanics hand tools, you will need to obtain or borrow:
Welder capable of handling 3/16” mild steel—unless you plan to cut parts and pay someone to weld them together for you (no more than 1 to 1.5 hours of labor);
Handheld band saw or (less preferable) hack saw;
Dremel with cut-off wheels;
Drill motor or die grinder and carbide rotary bits;
Drill press (though it is possible to use good hand drill);
Tubing bender and cutter for return fuel line.