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The trick is knowing what is a critical dimension and what isn't to ensure that your component functions satisfactorily. Hence you can machine it accordingly and choose the appropriate method and material. It is not only about absolute dimensions, it is flatness, parallelism, cylindricity ...

The design looks unnecessarily complicated. My charger has a 3d printed backplate and an extension shaft and so far has been fine.

The problem is that my code is so bespoke to my application as it is a twincharger with a bypass valve. Most of the code is actually concerned with signal conditioning and hysteresis for my engine speed sensor to make it useable. Delving into other people's code is normally a nightmare as you...

The only time I have failed an ESC is either when the command to ramp the motor to max speed or stop it from max speed is too fast. On the closing side you have the inertia of the compressor slowing it as well so ensure that the rate the motor stops is slower than it opens. Just my experience

I had the first issue with the system. Unfortunately my ECU does not support CAN so I used a second TPS and initially fitted a non automotive potentiometer as the throttle input. I thought I might get away with it but vibration and heat killed it. So a quick redesign with a conventional TPS and...

Maybe but normally a boosted engine uses manifold pressure for the load input so it is easy to map for the additional pressure. However I suspect the power commander is a piggy back module that cheats the map in the Ecu. Maybe OK but certainly not ideal especially if the supercharger...

OK if it just that simple. In my application I need to control the motor with multiple dependent input conditions and also a supercharger bypass valve all of which can be mapped accordingly. Then a more complicated control system is required. Just depends what you want to do with the system.

You need to provide extra fuel for the denser air when it is boosted and also be able to retard the ignition for the same reason. I would doubt that the standard maps for the engine would be safe for a decent level of boost so you would most likely need a reprogrammable ECU

The arduino is way way more configurable. Once you spend a few hours learning it then it then you have another dimension to the project. An additional benefit of doing new projects, especially one of this type, is to learn new skills which can be used on other projects.

By far the most efficient way IMO is to use the servo library from the arduino. The ESC accepts this as a PWM value from the arduino. Using whatever input you want i.e throttle position , boost pressure, engine speed etc you can send an appropriate PWM value to the ESC to control the speed. You...

Of course it will be OK as long as you map the ignition correctly and it does not knock excessively. Ensure that the fuelling is correct (obviously)

That code looks extremely primitive. The most efficient way to drive an ESC is via the servo library in arduino and ramp it from the neutral arming position to full speed at a rate that is safe for the ESC

How do you control the motor from the ESC? Do you use an arduino? If so the exact coding is very important

How exactly are controlling the motor at the moment?

In reality the simplest way to improve fuel consumption for any engine is to increase the compression ratio which improves cycle thermodynamic efficiency. This in conjunction with ensuring each cylinder is running at the optimum condition at each speed/load will significantly improve fuel...

One final modification I have just made for the twincharged installation is an uprated ESC. My original one was close to max for the TP motor and sooner or later I suspect it would have had an issue. So I have installed a Hobbywing Max series ESC which can handle a very high instantaneous...

I really don't understand your difficulties. As for drilling and reaming, of course you can get perfect results if you use correct sized drills and reamers. The final dill needs to be around 0.1mm less than the reamer nom size. I have found drilling the hole be very progressively gives best...

Which is why those heat sinks work well and are much simpler however the body of the motor needs to be smooth for max heat transfer. I was originally going to go down the water cooling route as I have a charge cooling circuit already in the car but tried the heat sink first as it was way simpler.

If the motor produces 6kw it wont dissipate 6kw of heat, more likely around 600w which is 90% efficiency

I have not accurately measured the current, only on a bench test for single phase comparison purposes but the spec of the motor is 300A and that agrees reasonably with the single phase crude measurement. The average duration of the spool is only around 3s although this could repeat maybe 3 times...