[travelers]

Originally Posted by PLstang

Do yourself a favor and read through the instructions before you even start. KB has a weird sense of humor sometimes.

Anyways, you'll understand why your doing somethings if you read through the instructions first.

That's for sure. I would read them a couple times.

[sqidd]

Originally Posted by travelers

That's for sure. I would read them a couple times.

Mine was supposed to have instructions?

[Preston951]

That's great man! The Stage 1 KB is on the top of my blower list right now. It won't be happening for a few years, but when it does...

Out of curiosity, why did you choose KB over Whipple/Saleen/other twin-screws? From what I've read, KB doesn't have the best customer service and all other supercharger brands have great communication with their customers (I think ProCharger is the best at that). Just something I've wondered about.

BTW... If you don't like it, I'll pay for shipping & take it off your hands!
(Jealooouusssssss )

[KlrStng]

Well, I just got done with the first long evening of work. The first step I took was pulling the valve covers off and getting them degreased and sanded down, ready for powder coating.. i am having a buddy powder coat them with the chrome-like stuff then a clear.. he is doing it for $50 as long as I had them ready to spray, and after a few hours of scrubbing them, they are about as clean as they can get.. and I sanded them down pretty smooth too..

I also got through step 59 (of about 400). Some steps I had to do as I was taking the valve covers off, and then I went back and labeled all the wires (just in case I forget) and proceeded to take the manifold off and clean it all up. There was a bunch of clean up for the valve covers too, and they are all ready to go back on as soon as I get them back. I even took a trip to the auto store to get some ATV, and I picked up some odds and ends like anti-seize for the plugs. I have been taking lots of pics, but I am too tired to get the camera from the garage, so i will post pics tomorrow. Step 60 is to drain the radiator, and I don't have a decent drain pan handy so I will pick one up tomorrow.

The manual is about as detailed as possible, but the funny thing is there are like 10 supplements that replace or add to various steps. I read through those and spent a little time thumbing through the 400 steps, and so far it is crystal clear.. the hardest part was getting the vacuum line out of the brake assist.. instructions just said pull it out, but it don't come out that easy...

I am going to go into work for a few hours tomorrow, even though my brother (my boss) told me to stay home and work on it.. I gotta keep up appearances at work, and everyone knows I got the supercharger, so I don't want too much jealousy if I don't show up..

One of the new steps is installing and mounting the Diablo MAFia, which I think is a new addition to the kit.. It isn't listed in the website and the instructions for it are new.

As for why I chose the KB, there are a lot of reasons really, and the biggest of all I can't really get in to, but let's just say the price was right.. it helps to know people sometimes. I was planning on getting it later in the summer already for full price ($6500). The price for the kit was cheaper than the equivalent in Whipple. I looked at the E-Force, but the early hiccups scared me, and I would have wanted the Tillman Speed 7psi kit at about the same price. The Techco is too damned expensive, and after hearing the audio clips around the internet, I just didn't want it, especially given the price for a basic setup ($7500). Saleen is scary to me right now because of all the rumors and such about the company being defunct.. Brenspeed said they are doing well under the new ownership, but to me it would be like buying a Pontiac right now.. I don't like the way the vortech/paxton sounds at idle, and I really liked the idea of instant power of a twin screw. Everyone tells me to avoid the roots/TVS stuff, plus the power just isn't there for the price. So after all the research, the KB looked like the way to go for me..

Now I need to hit the sack before I fall asleep at the keyboard.. all this excitement has me tuckered out. I will post some pics in the morning, and get some more work done tomorrow.. A new theater opens tomorrow, and me and my son are going to go see Terminator on their biggest screen.. So I don't know how far I will get, and then my daughter's birthday party is Saturday.. Should still be done by Monday though.. unless I run into problems..

Just as a side note.. I went to change the plugs and couldn't find my 9/16" deep socket, and it was after 9pm, so I sent my wife to Walmart to get one.. she found a full set and brought it home. The socket didn't fit! It was deep enough, just not big enough.. I double checked with a good box end wrench and its exactly 9/16", but the socket was too small.. so in the end she returned the set so I either have to find my socket or buy a new one tomorrow.. I did get the plugs gapped with my bench vise though..

[KlrStng]

Originally Posted by Preston951

That's great man! The Stage 1 KB is on the top of my blower list right now. It won't be happening for a few years, but when it does...

Out of curiosity, why did you choose KB over Whipple/Saleen/other twin-screws? From what I've read, KB doesn't have the best customer service and all other supercharger brands have great communication with their customers (I think ProCharger is the best at that). Just something I've wondered about.

BTW... If you don't like it, I'll pay for shipping & take it off your hands!
(Jealooouusssssss )

Somehow I don't think your offer would be good for me..

I addressed your questions in my long post, but just a note on customer service with KB.. Their people are great, it's just hard to get a hold of them. The company is sort of stuck in the past, not utilizing electronic means of communication really well. Most people have really good luck with the product, and once they get a hold of someone for tech questions, everything gets answered. A couple people have had issues and are not satisfied with the answers they got, and I can understand their frustrations. The instructions and supplements really address every issue I have every seen on this supercharger, and it all makes perfect sense.. (ie the belt problems are usually from bouncing off the rev limiter, causing stress on the belt and the tensioner). The one thing they are good at in the instructions is disclaimers.. Heck, they even have a big warning for when you disconnect the fuel line (NO SMOKING WHEN DISCONNECTING THE FUEL LINE). I found that kind of amusing. The sad thing is, each disclaimer came from some customer actually doing these things against common sense or KB's suggestion.

I just hope I don't have any issues, but if I do I am sure I will eventually get them taken care of. It just might take a few days...

[guitarist9008]

Sounds like you're going to be a very happy man soon. Hopefully everything goes smoothly.

[jonballi]

Wow...I never would have guessed. It looks like the install would be super easy since the blower sits on top. I would have thought a turbo would be hard to install.

Sweet purchase btw.

Originally Posted by KlrStng

Being an amateur, probably 25 hours.. maybe a little less.. A pro that has done it before could probably do it in 8 hours. There are about 4000 parts here.. I think with a welding torch and some tires I could make a whole car from all the parts in these boxes..

I'm gonna get the car on jack stands tonight, just in case I need to get under it since I can't fit a jack under the car unless its rolled up on blocks first. Then I will get the valve covers off and get them to my buddy who will powder coat them this weekend. That way I can have it all back together by Tuesday..

I don't have a gauge pod yet, but the O2 bung is in, and I have the wideband already. I might just try to fit it between the 2 vents in the center.

I just sold one of my guns and my CAI and tuner are up for sale so I can finish buying the gauges and stuff.. Seeing the blower sitting on the chair next to me as I type makes it all worth it.

I plan to take lots of pictures and post the whole install.

[KlrStng]

OK, here are some pics..
First is what it looked like before I started..

Second, Third, and Fourth are the parts, sort of layed out.. Once I am done with removal stage, I will lay everything out for R&R stage.

Fifth pic is about halfway through first evening, valve covers are off and just about done with prep for putting them back on.. I covered the exposed cams/valves/springs with rags to prevent anything from accidentally falling in.. and to keep the dust off.

Sixth pic is the pile of parts starting to come out.. that pile keeps growning...

Seventh pic is my son degreasing and scrubbing the valve covers.. He got home from work just in time to do more work. Notice the boxers hanging out in back.. I will never understand that one..

Eighth pic is just after I pulled off the manifold. I was surprised how dirty the intake ports were.. only 15k miles on the car and for just fuel and air those are pretty dirty. I carefully wiped the dirt and gunk buildup off the surface and taped it all off.

Ninth pic is how it sits now. Alternator and belt removed, about to drain the coolant and remove the crosover tube..

More to come, stay tuned.

[KlrStng]

Oh, one more thing: I have to give credit to TacoBill. I referred to his HOWTO on MustangForums for removing the valve covers.. I couldn't figure out how to get the plastic parts out of the covers and his guide had some great info. I also learned about the spots I need to put ATV silicone when I reinstall the covers. I highly recommend checking those out if you ever do a project like this.

[monk3619]

Nice, just finished installing my techco super... sicknesss

[Preston951]

Oooohhhhhhhhhhhhhhhhhhhhh!!!


I'm getting so excited man!!! I just installed my eBay oil separator today & it was great... Can't imagine the fun you must be having!

(Call it the placebo affect, but my car seems to be running so much better! Got 'er up to 60 & floored it... Damn! 80 in like 2.3 seconds! )

[KlrStng]

Well, I got a lot further after working on it for the last 12 hours.. I did take a couple breaks to go see the new Terminator movie, and also to go pick up my valve covers. The powder coating turned out great, but putting clear over the chrome powder coat dulled it to a flat gray, so we just have the chrome powder on now. I guess it doesn't react well to chemicals like degreasers, but basic soap and water is fine. It isn't super durable, not even close to chrome plating, but for less than $50, I can't even begin to complain. The finish is very much like the polished aluminum. I am letting the powder coat set up a little more before installing them, but I hit a point tonight that will make it difficult to put the covers on if I continue, so I called it a night (at 1:30 am!) and will start again in the morning with the passenger valve cover.

I got the plugs in, which I was worried about, being as there are so many horror stories about people breaking off plugs. Took about 50 ftlbs of torque to break them loose, but I shot some penetrant in last night, then a little more after getting a quarter turn out of them, and they came right out. I used a socket, a screwdriver, and a bench vise to gap the plugs to .035". Not the best way in the world, but better than using a $40 tool to do it.

I hit 2 of the supplemental instructions and got really twisted around.. Took my time and it worked out, but kind of a pain. The filter setup uses the factory airbox top and a diablo mafia, so there are like a dozen steps different, and the documentation is not up to the standards of the rest of the book. The hardest thing is determining what screws to use where.. NOTHING is labeled, so you just have to know that the screw you are using (ie M6x14) is the right one. There is almost a method to how it's bagged, but it's a pain by any measure.

There are actually more than 400 steps.. I got to like 145 and that was the end of disassembly, then it starts over at step 1, so there are about 550 steps. I am on like step 28 of assembly, but I have done steps 88-97, which is wiring the MAF plug.. I had to open all the loom, pull some wires back, solder in a plug, then crimp some pins and pin a plug, then cut the end off the plug and solder the factory one on to plug into the mafia. I have the pin crimper, which made that part a breeze, but without the valve covers on, cutting wires to length is a guessing game.

The bumper and light are out for the air filter install, which goes below the passenger light. The whole process is a mix of supplemental instructions that overlay and jump around, making it really confusing. In the end it went together, but there are some details I have to wait another 100 steps before I can finish, and it is exhausting just keeping track.

The coolant thing was a pain.. I drained the coolant, but disconnecting the head coolant lines poured another gallon or more into the valley, which made a real mess.. 3 rolls of paper towels later, its all cleaned up. Disconnecting the lines from the heater core was a chore too.. once I figured it out it was easy, but I struggled with it for like 10 minutes.

Despite my daughters birthday party tomorrow, I should get a lot done and be well on my way to finishing on Sunday. Once the valve covers are back on, the rest is just following instructions. It is getting tight in the front of the engine compartment again. The ECU gets relocated in front of the belts. I knew it was time for bed with I had to look for 5 minutes to find the harness to plug the ECU back in.. I had moved it to where the battery normally sits to keep it out of the way, and I sat there looking for the plugs for like 5 minutes.. If I weren't so tired I would have laughed..

I will post more pictures sometime this weekend..

[John10]

keep up the good work, congrats on the purchase

[KlrStng]

I thought I would jump on this morning before getting started and give a quick update. I made a ton of progress yesterday, but by 11pm things werent working out really well so I called it a night. When frustration sets in it's time to sleep.

The intercooler was a particular pain in the butt. Apparently they went to a bigger heat exchanger, and the pump is mounted seperately. This is fine except the pics they give to explain the assembly are a bit weak, and the manual is a bit off on the hoses and such as a result. Things didn't fit quite right, and the hose going to the pump has me worried. It is a thinner walled hose and has to rest up against some metal right at a seam. I filed the seam down as best I could, but I worry that vibration and flexing of the frame might wear into the hose a little, possibly eventually cutting it. Unfortunately there isn't any alternative unless I go buy a bunch of 90's and clamps and reroute it a different way. The problem there is once I add a bunch of connections the potential for leaks goes up. I bent some of the A/C lines out of the way and I took some pressure off the coolant line, so I am hoping it will be OK.. worst case I have to pull the bumper off and route a new hose to the reservoir.. not too much work really, and the chances are slim that it will ever wear through.

Aside from that, there was a ton of wiring to undo then do again. I went through a full roll of electrical tape already, cutting loom and rerouting wires.

The valve covers went on beautifully, and look great. Now that they are back on the wiring is all in it's proper place again and the only wires I have left are for the windshield washer reservoir. I ran out of butane in my solder torch last night so that was my stopping point. I have to go to the hardware store and pick up a couple items and finish soldering the extension for the washer pump, then route it and install the reservoir, and I will be ready to put the intercooler reservoir on. After that, I think it's all mechanical. Tensioner and idlers, alternator, manifold, and supercharger.. I hope to make great progress today.

As soon as I get some time I will download all the pics, edit them, and post them all.

[KlrStng]

What a long day! I pulled about 12 hours today, which puts me right at about 30 hours in so far. Granted, about 4 hours of that was spent on the valve covers, and perhaps another hour just looking at that beautiful polished supercharger, so its still taking about how long I figured.

I am pretty much done under the hood, with the exception of gauges (AF is up to the drivers side firewall, just need to get it in the vehicle), and the boost-a-pump. The BAP should take me a couple hours, and if I skip the gauge install for now, I can start the pre-flight and start it up.

Things went OK today. There was a little disappointment, a lot of frustration, and my knees and back are killing me.. but overall there was some great progress.

The biggest problem is the filter. The nature of the deal made it so I ended up with the california emissions filter, which is the factory air box top and a K&N filter as opposed to the cannister filter. The problem is, my Street Scene Gen1 front bumper has a big vent right where the filter sits, and the filter corner actually sticks out the hole. Definately ugly, and needs to be changed. I will have to see about getting it exchanged next week. The square filter box setup uses a Diablo Mafia, but I think it is not used with the cannister type... The Mafia was mounted where they recommended, but it didn't work out too well, and I didn't want to disassemble 40 parts to fix it.. kind of a pain..

There was a lot of frustration with the vacuum lines, but in the end we got it worked out. The only other real issue was the supercharger going on the manifold. The bypass valve assembly was hitting the fuel rail pressure sensor setup, so we set the supercharger gently in place while I removed it, then got everything in line, and put it all back together. The problem was the polished aluminum was scratched on the manifold a little.. I should be able to buff it out, but it still sucks.

There is a ton of supplements to the instructions, and many are not clear at all, which led to some delays as I tried to work out what needed to be done and what parts I needed to use to do it. There is a supplement that says you don't need silicone when placing the supercharger on the manifold because there is a rubber o-ring there now. Then I discovered the inlet had an o-ring too, but it didn't mention anything about it. I didn't use silicone since the manual clearly showed putting it on a version of the supercharger that didn't have the o-ring, but it would have been nice for the supplement to say that both mating surfaces have rubber o-rings and don't need silicone.

My next few posts will have pics...