I recently drove a 100% California smog legal LS3 996.
I'm told it's the first fully legal LS swapped Porsche.
Amazing, sorted swap.

 

I think that the tiny Nippendenso models that go on an early Honda FIT put out about 90 amps...They are only about 4 inches in diameter..might be a solution to tight quarters...jus sayin..

 

TonyG had a 100% legal swap before the LS3 even debuted, lol

 

^ Like. I will search.

 

Last I removed the airbox to survey the room I have, I have plenty.

Spencer: Do you know if an alternator can be driven with a single v-belt? Thinking ahead of moving the alternator to the PS place but still use the PS crank pulley.

 

that's how i was going to do it, using the PS pump drive pulley and a v-belt pulley from an old volvo or something on the alternator.

"serpentine multi-rib" belts only really came about in the late 1970s...before that everything was "single V belt", alternators, mech fans, AC compressor, power steering, etc.

 

So I put together a rough budget for this project. Prolly left a few things out which I will compensate for by adding 50% to my estimate which may not be enough. But here goes.

ECU $609
MS3 $409
Other sensors $50
Wideband O2 $150

SC $690
MB M62 $170
Custom Pulley Set $270
Water Inj $150
Tube Fab $100

Alternator Relocation $150
Smaller Alt $100
Bracketry $25
Pulley Mods $25

Electric PS conversion $135
Volvo S40 PS Pump junkyard $50
Fittings $25
Elect $35
Mounting $25

Total $1584

 

Probably in the ballpark, but IMO designing in a proper intercooler is a better idea than water inj.
It's a cool idea, and it definitely works, but having to refill a tank and having another semi-complex system of switches and pump(s) sounds like a PITA.

Check out these guys for a pulley, I sent them a stock Ford SC pulley to get dimensions from, and had them make me a custom larger (to get underdrive) lower-boost pulley for ~$160 shipped.
I bet if you sent them your MB pulley they could whip up a solid (non clutch) version to fit your needs.

http://www.southfloridapulleyhq.com/

 

The shaft on the MB M62 is splined which is a deal breaker for many of these after market companies. I'll send them an email though and ask if they can do one.

 

then perhaps the solution is to have the MB nose shaft turned on a lathe to remove the splines, and make it (if possible) the same OD as the GM-style pressfit pulleys.

 

More on the pulley cost
The $269 includes 2 pieces. The splined hub that mounts on the shaft, and the pulley that mounts to the hub in a "quick change" arrangement. New pulleys after that are less than $100 (from Hungary.....)

 

You are probably right but I want to avoid the ducting and fabbing. Running a 1/8" nylon tube from the washer fluid tank to the SC output sounds easier to me fab wise. At the boost levels I am targeting I probably do not need IC so this is just R&D and play for me. I would be running the injection off MS3.

Now for fun project afterwards I was thinking of using the AC (its right there) to do the intercooling. Fashion up a small evaporator and expansion valve right at the SC output and pump the refrigerant up there. With a 40F evaporator you do not need a very big heat exchanger. Have a valve actuated by the ECU or vacuum to direct the refrigerant to the cabin evaporator when off boost. Should work right?

 

Ford tried that on the Lightning as an optional extra.
They use the AC to passively cool the water in the air-water intercooler system while driving around so it gets super cold. Then when you actually go into boost the water is at 35 degrees or whatever rather than roughly ambient which helps a LOT in cooling efficiency.

You could do similar with your to-be-injected water.

If you want to directly "air condition" your boost, not gonna work.
The 944's AC system takes 8-10hp to cool ~300 cfm from the blower fan from 100 degrees down to 65 or so in the cabin.
Air coming out of the blower will be 250+ degrees, lol, and the compressor turns off when you got WOT

 

Good to know, saves me some work.

 

Why dont you guys just use a stock 951 cooler? It fits right in the nose, and will do the job for your SC engines