Once the supercharger was in place and the heat exchanger was installed, it was time to take care of a bunch of little things, like the intercooler reservoir, intercooler pump, pulleys, wiring up relays, etc. This ate up some time, but was actually an enjoyable part of the build. You'll notice in the pictures that the power steering reservoir is mounted close to its original location. I just cut the mounting bracket off and welded it higher up on the bracket that attaches it to the head so it would clear the s/c snout. I also had to cut a relief behind the s/c tensioner in order to let the wiring harness pass behind it in that location.
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Here is my chosen location for the intercooler pump. Most people put it on the passenger side, but I mounted mine on the drivers side where it could draw straight from the reservoir, push the fluid down through the heat exchanger, and then up into the intercooler in the s/c lid, and then of course back into the reservoir.
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I put the pump relay on its own circuit. The main power for the pump is running straight from the main battery post on the fuse box. I did take switched power for the relay from the closest pink wire that I could find. If anyone knows what this circuit is or if it cannot handle the extra 0.8 amps required to open the relay, please let me know and I will reconfigure it, but with such a small load, I figured I was okay taking switched power from just about anywhere.
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And finally, here is the "almost finished product". In this picture, you can still see some of the relay wiring, which will be cleaned up as well as a few other things. Seems like there are hoses and wires going everywhere. For the evap purge solenoid, I used the stock plastic line but I had to bend it to fit its new location on the supercharger. I did this by taking the largest diameter wire that would fit inside the line, gently heating it up with a propane torch and bending it to fit. It didn't take much heat, and having the wire inside kept it from collapsing while I bent it into place. I would have just eliminated the system altogether, but I want this build to be completely emissions legal, cats and all.
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The intercooler reservoir is from a Saturn ion. I just went to the junkyard, searched around until I saw an expansion tank that was just the right size, and brought my prize home to install it on my caprice. You'll notice that I have the return line running into the vent tube instead of the intended return port as it was much too small for my liking. I also modified the lid so it let the coolant pass easily back into the tank with no extra resistance. The whole intercooler system seems to flow very well. Time will tell if my intake air temps stay withing reason.
I scheduled an appointment with my dyno tuner and he is booked until the middle of August, so it'll be a while before I get the car dialed in just right. In the meantime, if anyone knows any good dyno tuners in Utah that will work on GM cars, please let me know.