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 $2,337, depending on various options discussed below. Again, this is not yet a complete list, as the remaining silicone snorkels, T-bolt clamps, and aluminum joiner tubes will add another significant chunk, perhaps $150. Plan on about $2,500 to be conservative.

Add $150~350 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 or another self-service auto recycling yard. See the harvesting a supercharger instructions for details. Buying one without the manifold, etc., saves money.

Add $62 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 its bearings may not hold up well to the increased side-load from the serpentine belt tensioner.) 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. Need help with this? Just give us a shout.

- 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.

PART 1 - SUPERCHARGER

• Eaton M45 (45 C.I.D.) supercharger, model no. 207018 or 206127, from 1999-03 Mercedes Benz SLK230 Kompressor coupe and 1999-00 Mercedes Benz C230 models without electronic clutch - $54.50 at U Pull-N-Pay (including core & environmental fees) (add $150~$250 for pre-pulled unit).

• Creative Spridgets M45 manifold - $235;

• OEM Mercedes supercharger manifold gasket no. A 111 098 03 80 - if you can find one, very cheap. However, if you cannot locate one, we suggest using Permatex Ultra Gray sealant or Yamabond 4 Motorsport sealant. Either is fine, as all you’re doing is sealing against air moving in or out of the rotor chamber;

  *Note to overseas customers: if you have no source in your area for the gasket, contact us upon ordering your M45 manifold, and we can obtain a gasket in the U.S. and include it in your parcel for our cost - $14.09 w/shipping to our facility, last time we checked (Pelican Parts online).

• 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 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 – 3/16” thick (.1875”) x 6” wide x 12” length;

  • Hot rolled mild steel angle iron – 3/16” thick (.1875”) x 2” wide x 10” length;

  • Cold finish mild steel rectangle – 3/16” thick (.1875”) x 1” wide x 12” length;

• Rear mount:

  • Cold finish mild steel rectangle – 3/16” thick (.1875”) x 3” wide x 6.5” length;

  • Hot rolled mild steel angle iron – 3/16” thick (.1875”) 1.5” wide x 5” length;

  • Hot rolled mild steel angle iron – 3/16” thick (.1875”) 2” wide x 12” length;

    • Fasteners for supercharger-to-mount flanges - 304 Stainless 5/16-24 x 2-1/4” socket cap screws, 304 Stainless 5/16 flat washers, 316 Stainless 5/16-24 nylon lock nuts (Albany County Fastener) - $7.50.

    PART 2 - PULLEYS & DRIVE BELT

    *Note: check out the instructions for converting to serpentine belt drive.

• 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;

  *Note: we recommend starting with a 3.1” pulley (2.9” if you operate at higher elevations), but Smoothflow offers them in nine (9) different sizes to fit the hub so you can reduce or increase the amount of boost. Additional pulleys are $50 each. See the table of pulleys and resulting drive ratios in the tuning the system section of the instructions.

  *Below is an image of what you net for $18 less than the Moss Motors ‘high boost kit,’ which consists of a single smaller pulley choice, adjuster bracket, and hardware. You get three additional pulleys from Smoothflow, a second idler and bushing in the parts list, and a fastener from your hardware store:

• Idler pulley (2 needed if running 2 idlers) – Dayco # 89535 54mm dia., 30mm wide Rockauto.com, various sources - $20.79;

  *Note: if you are running either an early model down-flow radiator or the VW Rabbit (Golf) radiator conversion, you will need one additional Dayco # 89535 idler pulley, two spacer & idler bushings (next item), a 3/8” x 3” bolt, three washers, and a nylock nut.

  *Also: if you plan on running one of the smaller, high-boost pulleys discussed above, you may need to add a third idler pulley and purchase a shorter belt (listed below), to take up the slack created by the smaller pulleys. See the installation instructions section on fabricating the front supercharger mount for how to add a second and third idler pulley.

• Rotary idler pulley bushing (2 needed if running 2 idlers) - .375” Id. x .590” shoulder length - texaslawnmowerparts.com part # 10969 - $5.10 plus shipping (also eBay, same part # $7.17 free shipping) or (mfgsupply.com $1.19 plus shipping, part # 13-10969)

  *Note to overseas customers: finding this part may be difficult outside the U.S., so if you are ordering other parts, contact us and we will obtain one or more bushings and include them in your parcel for our cost ($1.60 each, plus up to $6.95 shipping);

• Belt tensioner – Dayco # 89258 or Gates 38159, Rockauto.com, various sources - $16;

• 5-rib serpentine belt - Dayco # 5050570 (alternate # 5PK1450, replacement # 570K5, Daytona brand and others) Amazon, various sources - $7.81. If you need more or less length due to variances in your mount fabrication, Dayco # 5050580 is ~ .80” longer (alternate Daytona K50580, Gates K050580); Dayco # 5050565 is .59” shorter. Dayco has a length look-up tool on their website.

part 3 - Carburetor & ignition

• Rebuilt HIF44 carb - Mini Mania for $369, or $542 Mini Spares (plus shipping from UK), or Moss for $699.99;

• SU short damper cap - CUD 2901 (as needed, to afford bonnet clearance) - $16.69 (plus shipping from UK) - Burlen Co.

• BCA needle and 8 oz. spring for HIF44 carburetor (prices forthcoming) - Burlen Co. in the UK, or Joe Curto, Inc. in the USA. Joe can supply any parts for your HIF44—such as throttle spindle seals or float chamber O-rings, if yours are damaged;

• Minispares C-AHT770 manifold - $66.81 including shipping from UK;

• Creative Spridgets ‘convertible’ SU HIF44 blow-through ram pipe & snorkel adapter - $90.00 (includes hardware) and restrictor rings - $30;

• Float chamber vent check valve - ACDelco 14047619 GM Original Equipment Cruise Control Vacuum Harness Check Valve - $9.41;

• Cooler spark plugs - NGK BPR7ES (5534) - $8.00 (set of 4);

• High performance air filter - K&N no. RU-3190 - $42.99. Any air cleaner that suits your mounting location and needs will do;

  Optional - for tuning carburetor: “SU Needle Profile Charts” booklet - Burlen Co. or Mini Spares (online in the UK), part no. ALT9601, $5.16 plus shipping to U.S. (much less within UK).

part 4 - cooling

• If running down-flow OEM radiator or 1979 VW Rabbit/Golf radiator with 1275cc engine - Creative Spridgets thermostat housing adapter - $85. Fit either a 3/8” NPT brass plug or ACDelco 213-4396 temperature sensor (as little as $9.00 online). In either case, remove the thread sealant that may come on the fitting (a wire brush works well) and apply teflon tape.

part 5 - supercharger bypass circuit & intercooler

• 2002 Mini Cooper S supercharger bypass valve - $48.95 (Amazon and elsewhere).

• Creative Spridgets supercharger bypass valve adapter - $27.50 (includes hardware & special spring to recalibrate the bypass valve per the installation instructions - replacement springs may be found at The Spring Store);

• Gasket for bypass valve adapter - Felpro 35064 - $1.77 to $2.49 (Amazon, Autozone and elsewhere);

• Aluminum turbo ‘blow-off’ pipes (2 pcs) - 2.5" Turbo Blow Off Valve Flange Adapter Pipe for Type-S RS BOV - $16.00 (Amazon and elsewhere);

• 1994-2005 Cadillac de Ville engine coolant thermostat housing/water outlet Dorman no. 902-2010 - $14.27 (eBay, free shipping);

• Gasket for Cadillac thermostat housing - Felpro 35064 - $1.77 to $2.49 (Amazon, Autozone and elsewhere);

• Hose for bypass circuit Gates no. 21972 - $14.98;

• Joiner for bypass circuit hose - 6061-T6 Aluminum Joiner Tubing with Bead Roll, HPS AJ600-125, 16 Gauge, 6" Length, 1.25" OD, 0.065" Wall Thickness - $16.28 (Amazon and elsewhere);

• Intercooler from 1997-2000 Audi A4 Turbo 1.8L (and Quattro), 1998-2001 VW Passat and Jetta Turbo diesel (OEM no. 058145805A), CFS Imports no. 6032 / ECS Tuning no. ES#3545381 - $65, ecstuning.com; Spectra no. 4401-1110 – $110.79 Rockauto.com, various sources or pennies on the dollar at wrecking yards;

• Tight-radius, 180-degree 2” silicone snorkels for intercooler, from do88 (Sweden) part no. SB180G51 - $25.60 ea. (plus ridiculous shipping), or from Pegasus Racing part no. E180.51-BLACK - $37.99 ea. (plus domestic shipping);

• Universal 2” silicone & aluminum intercooler pipe kit w/T-bolt clamps - eBay $65, Amazon $90;

• PCV valve (for two-stage PCV system, if desired), OEM on 1968 Chevrolet Impala 4.1L 1BL OHV 6cyl (and many other vehicles), Fram FV237, or ACDelco 2144834, or Autozone no. PCV1126DL - $1.39;

part 6 - high pressure fuel system

• Fuel pressure regulator:

  • If you will not later convert to EFI, preferable is the stock MG Metro unit, Malpassi - Mini Spares # FPR012 - $56.57;

  • If you do plan on EFI later on, use a generic regulator, such as the Aeromotive 13301 Universal Bypass Regulator - Summit Racing - $131.95 (base pressure adjustable from 3 to 20 PSI with standard spring, (installed) or from 20 to 60 PSI with high-pressure spring (included);

• Optional: integral fuel pressure gauge, such as Auto Meter 2172, 0-15 psi (for non-EFI, carburetor only setups), or Auto Meter 2179, 0-60 psi (for EFI-capable setups) - Amazon and elsewhere - $35~$40;

• High-pressure fuel pump:

  • If you will not later convert to EFI, stock MG Metro Turbo pump

    or comparable (160 LPH / 42 GPH) - Mini Spares, $85.80;

  •  If you do plan on EFI later on, universal pump, such as Walbro GSL-392 (255 LPH / 67 GPH) In-Line Fuel Pump w/fittings, hardware - eBay and elsewhere $46.99

  • In the UK and elsewhere, it may be easier to find the Bosch 044 - eBay and elsewhere $65;

• Fuel pump relay, 30 amp universal w/pigtail – Amazon, eBay - $3.99;

• Stand-alone surge or ‘swirl’ tank for in-boot installation on standard-body Spridgets, Speedmaster PCE131.1004 (Jegs and elsewhere, $70.29);

• Integrated surge/swirl tank & fuel pump housing for Bugeyes or for standard-body Spridgets to fit the tank and high-pressure pump under the bonnet or in the boot. Below are two choices to fit the popular Bosch 044 pump:

  • 1L Billet Aluminum Single Bosch 044 High-flow External Fuel Pump Surge Tank E85 (eBay - $38.58):

• 2L Billet High Flow Swirl Fuel Surge Tank AN6 Fitting & 044 External Fuel Pump (eBay - $65.99):

Optional: integral fuel pressure gauge only if using the Aeromotive Universal Bypass Regulator such as: Auto Meter 2172, 0 to 15 psi (for non-EFI, carburetor only setups), or Auto Meter 2179, 0 to 60 psi (for EFI-capable setups) - Amazon and elsewhere - $35~$40;

• High-pressure delivery line: 5/16” steel (or aluminum) line, 20’ coil (Jegs - $48), or nickel/copper line, 25’ coil (Amazon - $48);

  *Note: the above coil is ample for two cars. However, if your OEM 1/4” delivery line is damaged or has been removed, use the leftover line from this coil for the vapor recovery system discussed in the installation instructions.

• Low-pressure return line: for standard-body Spridgets running the Walbro pump and Aeromotive regulator - Allstar ALL40185 1/2" Diameter 25' Aluminum Coiled Tubing Fuel Line (Amazon and elsewhere, $31.91);

• Bugeye owners and those running the lower-volume Metro Turbo regulator and pump should not need a 1/2” steel return line; the Metro Turbo regulator’s hose barbs are 5/16” and a 3/8” steel return line should suffice);

  Optional - to create or modify vapor recovery system:

• Charcoal canister: if you have an early Spridget or Moggy without a vapor recovery system, you will need one of these - $71~$79 (English parts no. TKC1331, Moss Motors no. 367-100);

  1. 5/16” steel line (left over from high-pressure delivery line coil)

  Optional - for Cold Air Intake:

• Spectre 3” air duct mounting plate, part no. 8148 (Autozone, Amazon and elsewhere - $6.99)

• 3” aluminized flexible HVAC or automotive duct

• 3” hose clamp

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- 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…

• Or cut the parts and pay someone to weld them together for you (they should charge 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 or (less desirable) good hand drill;

• Heavy duty puller to R&R supercharger pulley, or rent one from us by clicking here;

• Tubing bender and cutter for delivery and return fuel lines;

• Bench vise (the bigger, the better - you will use this countless times while working on your Spridget).
  

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