Automotive Supercharging Course

Lesson 1 • Key Performance Metrics

Defines boost pressure, pressure ratio, mass airflow, and adiabatic efficiency. Students use these metrics to evaluate supercharger performance throughout the course.

Lesson 2 • Thermodynamics of Compression

Covers adiabatic and polytropic compression, heat of compression, and intercooling need. Grounds students in the physics that govern supercharger efficiency.

Lesson 3 • Principles of Forced Induction

Explains how compressing intake air increases oxygen density and power potential. Connects atmospheric limitations to the engineering rationale for supercharging.

Lesson 4 • Supercharger Types Overview

Introduces roots, twin-screw, centrifugal, and electric supercharger categories. Provides context for deeper dives in later chapters.

Lesson 1 • Intercoolers and Charge Cooling

Describes air-to-air and air-to-water intercooler designs, core sizing, and pressure drop trade-offs. Connects charge cooling to detonation prevention and power gains.

Lesson 2 • Centrifugal Supercharger Mechanics

Covers impeller design, diffuser passages, gear-driven step-up ratios, and boost curves. Links rotational speed to boost output for performance tuning.

Lesson 3 • Roots-Type Supercharger Anatomy

Details rotor profiles, housing tolerances, and bypass valve operation. Students trace airflow through the unit and identify wear-prone components.

Lesson 4 • Twin-Screw Compressor Design

Examines male and female rotor geometry, internal compression, and sealing. Contrasts twin-screw efficiency advantages over roots-type designs.

Lesson 1 • Matching Supercharger to Application

Overlays engine demand on compressor maps to confirm surge margin and efficiency. Students evaluate street, track, and towing applications with different criteria.

Lesson 2 • Engine Airflow Demand Calculation

Calculates engine airflow requirements from displacement, RPM, and volumetric efficiency data. Provides the demand-side input needed for compressor map matching.

Lesson 3 • Reading Compressor Maps

Teaches pressure ratio vs. mass flow axes, surge lines, choke lines, and efficiency islands. Students plot operating points to verify map compatibility.

Lesson 4 • Intercooler Sizing for the Application

Selects intercooler core volume and flow capacity based on power level and ambient conditions. Balances cooling effectiveness against packaging and pressure drop constraints.

Lesson 1 • Fuel Pump and Line Sizing

Determines pump flow capacity, line diameter, and return system requirements for boosted engines. Prevents fuel starvation under high-load, high-RPM conditions.

Lesson 2 • Injector Sizing and Selection

Calculates required injector flow rate from target power and brake-specific fuel consumption. Students select injectors and verify duty cycle stays within safe limits.

Lesson 3 • Alternative Fuel Considerations

Compares ethanol blends, methanol injection, and high-octane fuels for knock resistance under boost. Students assess compatibility with existing fuel system materials.

Lesson 4 • Fuel Delivery Fundamentals Under Boost

Explains how rising manifold pressure affects fuel pressure differential and injector flow. Establishes why stock fuel systems are inadequate for supercharged applications.

Lesson 1 • Piston and Compression Ratio Selection

Covers forged vs. cast pistons, ring pack design, and compression ratio reduction for boost. Students calculate effective compression ratio with a supercharger installed.

Lesson 2 • Cylinder Head and Valvetrain Upgrades

Addresses head gasket selection, head stud torque, valve spring rates, and port flow for boost. Ensures the top end supports increased airflow and cylinder pressure.

Lesson 3 • Lubrication and Cooling System Upgrades

Covers oil coolers, high-capacity oil pumps, coolant system upgrades, and supercharger lubrication needs. Maintains safe operating temperatures under sustained boost.

Lesson 4 • Cylinder Pressure and Engine Stress

Quantifies how boost increases peak cylinder pressure and the resulting stress on engine components. Establishes the engineering basis for hardware upgrade decisions.

Lesson 1 • Engine Management System Overview

Surveys OEM and aftermarket ECU architectures, sensor inputs, and actuator outputs. Establishes the control framework students will modify in subsequent sections.

Lesson 2 • Boost Control Strategies

Covers wastegate-style bypass valves, solenoid-controlled boost, and boost-by-gear strategies. Students programme boost targets and verify control accuracy on a dyno.

Lesson 3 • Data Logging and Tuning Validation

Uses data logs to identify rich/lean excursions, timing pull events, and boost deviations. Students iterate calibration until all parameters remain within target windows.

Lesson 4 • Fuel Map Calibration

Guides students through building and refining VE tables and lambda targets for boosted operation. Covers open-loop and closed-loop fuelling strategies.

Lesson 1 • Supercharger Mounting and Drive Setup

Details bracket fabrication or kit installation, supercharger alignment, and belt tensioning procedures. Ensures proper drive geometry for reliable long-term operation.

Lesson 2 • Bypass Valve and Boost Control Plumbing

Installs bypass valves, boost control solenoids, and vacuum/pressure reference lines. Verifies correct signal routing for accurate boost regulation.

Lesson 3 • Pre-Startup Checks and First Start

Performs oil fill, coolant level, belt tension, and boost leak checks before initial startup. Guides students through a controlled first-start and idle verification sequence.

Lesson 4 • Pre-Installation Planning and Safety

Covers workspace preparation, tool requirements, torque specifications, and personal safety protocols. Prevents installation errors that cause component damage or injury.

Lesson 1 • Reliability Tuning and Detonation Management

Implements conservative timing maps, knock sensor calibration, and heat soak mitigation strategies. Balances maximum power with long-term drivetrain reliability.

Lesson 2 • Scheduled Maintenance Intervals

Establishes oil change intervals, belt inspection schedules, coupler replacement, and rotor clearance checks. Prevents premature failure through proactive service planning.

Lesson 3 • Common Supercharger Failure Modes

Catalogues bearing failure, rotor contact, belt slip, boost leaks, and oil contamination faults. Students trace symptoms to root causes using a structured diagnostic approach.

Lesson 4 • Diagnostic Tools and Procedures

Uses boost gauges, data loggers, smoke machines, and stethoscopes to isolate faults. Builds a repeatable diagnostic workflow applicable to any supercharger type.