2008 Hummer H2 with Magnacharger TVS 2300
This update from: 12/19/2009

The Hummer H2 has arrived at our shop, and the customer is shipping us a new Hybrid Magnuson supercharger that Magnuson is putting together for our build. George at Kook's Headers is building us a set of 1-7/8 headers for this truck.
 


The first thing we will have to do is to pull the drivetrain out, so we can build the engine and send the 6L80E 6 speed automatic transmission to RPM Transmissions for their legendary Stage VI build.





Where do you put a 100 pound hood from a Hummer so it doesn't get damaged? No, that isn't a light bar on top of the Hummer... We laid fender covers down and carefully set the hood up on top of the luggage rack.

12/10/08



The engine and transmission are out of the H2, we have the engine apart and the block is getting machined. The transmission will soon be on it's way to RPM Transmissions to get rebuilt.

12/16/08



Shown is the bare block after the machine work was completed, which also required align boring for the Callies billet main caps.



We had to clearance the block for the 4.00 stroker crankshaft, you can see where we ground the block down by each cylinder bore.

12/18/08



The Callies Dragonslayer crankshaft is installed along with the Callies billet main caps and ARP main studs. We used a 4.0 stroke on the crankshaft to give us more cubic inches from the engine. This gave us a 416 cubic inch displacement for our Hummer. The added displacement is going to give this truck a lot more low end power, let alone the fact that we are adding a supercharger to it!





Dustin is checking the height of the pistons in the above photo. 



We are using Diamond pistons (pn#11555) and Oliver connecting rods for this build. This gives us a very durable combination for forced induction. We ordered the pistons to give us a 9.3/1 compression ratio.



We use ARP main studs on all of our engines, as they provide a much better clamping force than head bolts do. We installed our EPP blower camshaft, the spec's are .230/.240 .595/.608 on a 115 lsa. We have found this camshaft that we have Comp Cams grind for us to be very versatile. We have used it with twin and single turbo applications as well as with centrifical and positive displacement applications. This cam gives good midrange and very good top end power. It has a very cool sounding idle that makes it sound like a 60's musclecar. The larger displacement of this engine will smooth out the idle somewhat but it will still sound good. 
We installed a new timing chain and gears that are more durable than the factory parts. 
We are having the heads CNC'd, surfaced and stainless valves installed. CNC'ing the heads will give us more horsepower and the stainless valves are much more durable. With the horsepower this engine is going to produce we felt the stainless valves were a necessary addition for longterm dependability.


   1/2/09



Look what showed up today! This 2300 polished Maggie is one big blower! It is going to look great in the Hummer's engine bay! 



We got the 6L80E 6 speed automatic transmission back from RPM Transmissions, and the cylinder heads will be done in a few days.
We're ready to start bolting this drivetrain back together!

01/08/09



The cylinder heads just came back from getting a light cnc job done to them, along with Stainless Steel valves. We used Patriot Gold Extreme valvesprings even though they aren't needed with our blower cam, as this H2 is headed overseas to a very hot environment in the Middle East.  

 



The ports leading into this TVS 2300 Maggie have a peculiar shape to them that has us puzzled, we just hope they flow! This port design can be seen on Magna Charger's new TVS 2300 video.



The blower looks great sitting on top of the engine!



The engine and transmission are back in the truck, the blower looks great!



The ductwork supplied with the blower won't work with the factory airbox, so we're going to make it out of polished aluminum. We ordered a large aftermarket air filter to use with the stock airbox.



The Kooks headers once again look and fit great!



The Kooks cats flow great and will be a huge improvement over the factory cats!









We will have to make a short section of tubing to connect the exhaust together once we have the new Magnaflow exhaust system.


1/21/09



We are replacing the factory air filter with an Airaid high flow air filter. We're using 4.00" polished aluminum to make the inlet air tubing from the throttle body to the air box. 

 1/27/09



We made brackets to mount the transmission and oil coolers. The passenger side here originally housed the radiator overflow tank.





We drilled through the front sheetmetal to allow airflow through to the coolers.





We also drilled through the bottom of the sheetmetal in this section, and made boxes out of aluminum to direct airflow up into the coolers.





These aluminum airscoops should direct quite a bit of airflow into the oil and transmission coolers. This picture was taken before the assembly was fully installed.



Here is a view of the passenger side airscoop assembly.



Here is the driver side cooler assembly shown where the battery use to be located. We are going to be relocating the battery to the rear, and we have a chrome plated radiator overflow tank on it's way to replace the factory one.



The silicone pieces showed up for the air inlet tube, and we replaced the oil filler cap with a Caspers polished venter breather asssembly.



MSD LS2/LS3/LS7 coils were added, along with Taylor heavy duty spark plug wires and red DEI spark plug heat insulators.



Shown is the adjustable fuel pressure regulator, which is part of the Nasty Performance fuel system.





The fuel plumbing is braided hose with AN fittings, as can be seen in the above two pictures.



The Magnuson Hummer H2 supercharger comes with a much smaller intercooler/heat exchanger than their other truck kits come with. This is most likely due to the small grille area in the Hummer H2. Since we are going to be building a lot more horsepower than the typical Magnuson Hummer H2 puts out, we felt that it was necessary to include an additional intercooler/heat exchanger. The intercooler/heat exchanger in the above picture is one that we purchased that fits perfectly in the area that the oem transmission cooler had occupied. The brackets are welded to the intercooler/heat exchanger and then bolted to the truck chassis.



We are converting a lot of the black oem hose and vacuum lines over to blue, which will look good with the polished blower and the polished aluminum tubing we are using.



It is looking a lot sharper with all the blue rubber! We have a new higher amperage polished alternator on order from Nationsautoelectric.com that will really help to set off the engine bay.






2/6/09

Magnaflow does not yet have their 2008 system ready for production that they have listed for this Hummer. Their engineers said we could use their earlier Hummer version and all we would have to do is modify the tailpipe hangars. They were wrong.... The earlier systems use twin exhaust pipes running together down the passenger side of the chassis, while the '08 Hummer uses one large massive pipe. It uses an entirely different muffler for both versions. We're sending back the Magnaflow system we received and we ordered the 2008 Corsa Hummer exhaust system. The pictures of the Corsa system show the correct large single tube which then ends with dual tailpipes.



We installed two Odyssey dry cell 860 amp deep cycle batteries in the driver side rear compartment. We made a battery tray out of aluminum for the two batteries. These Odyssey dry cell batteries can be installed in any position, even upside down. Each one produces up to 1,700 cranking amps and are capable of 400 deep cycles. After two years of storage, these batteries can be fully charged in just one hour! This Hummer is going to be getting a lot of lighting installed on it, so these two batteries will come in handy.



The Hummer is alive! We fired it up today minus the exhaust system.

 
2/11/09



Now that is a muffler! The second of the two Corsa boxes showed up today, which contained the muffler.





Here is the supplied Magnacharger intercooler,  we talked to Magnacharger about it, and they thought the intercooler we supplied and installed would be sufficient, so we are going to try it and see what happens.

10/17/09

It is dyno time! We're not expecting big numbers out of this current combination as our blower was supplied with only a six rib 3.6 inch blower pulley. Magnacharger offers this kit with a 10 rib, why we were supplied a six rib kit is a mystery as Magnacharger knew we were looking for big horsepower.  We were told from a reliable source that if we drop down pulley sizes with this six rib kit we'll end up with belt slippage. We built an engine that can easily handle 1000 hp, but it looks like we're going to be severely limited with this combination.



The polished high amperage alternator arrived from Nationsautoelectric and we installed it and the truck is now on the dyno to get tuned!
This is one cool looking H2 engine compartment!





The intercooler looks good inside the grille. This Hummer is shown here getting backed on to our Mustang Chassis Dyno.



As predicted, we're not seeing much boost. It's making decent horsepower for the low amount of boost we're seeing. We'll get a better dyno graph posted, as this one has a time scale where the rpm should be.



It's back out! Brian at Magnacharger really came through for us and is swapping out the TVS 2300 we received for one with a cog drive that is designed for big boost. We're excited about what we'll see horsepower wise with this new blower!



Here are two pictures of the Corsa Sport exhaust system.





The customer had us order a spare tire cover that will help to protect the spare tire from the intense heat, that it will have to endure over in the Middle East.


03/05/09

It appears that we are going to be waiting quite a while for the new Magnacharger, as Magnacharger has some kinks to work out with their new cog kit. We all want this unit to be 100% perfect before we ship this truck overseas, so it is what it is. In the meantime we're adding some items the customer wanted us to install.



The first item are these chrome plated side vents from DefenderWorx. This picture doesn't do them justice as they really look sharp! We do wish they would of come with new fasteners (screws) as we installed the oem ones and it just didn't look good, so we went out and bought some stainless steel fasteners.



Next on the list, we replaced the fog light trim rings with chrome plated ABS trim rings from Putco. We also replaced the front tow hooks with stainless steel tow hooks from Aries.



We also ordered new stainless steel rear tow loops from HPC. The brackets that were supplied with these rear tow loops won't work on our H2, as the bracket assembly for the tow hooks is part of the spare tire carrier. We're going to use the tow loop part, and we're going to find some shims to properly space the loops in the brackets.



We installed the hood back on for the third or forth time, this thing is not light by any means! We have a new chrome plated grille to install and new headlights to install and wire in. We're going to go ahead and get as much done as we can while we are waiting on the supercharger.



The DefenderWorx billet chrome mini grille is installed, along with the new headlights.



These Starr Bi-Xenon lights are supposed to be about three times as bright as the standard halogen lights! The only downside that I can see to them is that oncoming traffic will flash their brights at the truck, thinking we have the brights on.


04/05/09

Our Saudi customer was having us build this Hummer for one of his customer's, and this customer got tired of waiting for the blower to get back to us, and has cancelled the whole project. This H2 is sitting at our shop minus the blower and is now for sale! If you are interested in purchasing this Hummer, please give us a call.


04/24/09

The build is back on! We are going to finish this truck for the company in Saudi Arabia that was having us build it for one of their customers. They will be using this truck for advertising, and who knows, maybe some lucky person will end up buying this truck from them!
Magnacharger is putting together a new polished 2300 eight rib blower for this Hummer, with a jack shaft and a cog pulley set-up on the back of the blower. We should have it in a week or so.


05/06/09

Brian from Magnacharger called this morning to let us know that we will have the new blower tomorrow!

05/07/09

The blower arrived this morning, it feels like Christmas has arrived!



This new 2300 has a jackshaft with a cog belt to spin the blower a lot faster than the first 2300 we were sent. The rear of the blower is shown in the picture.





The inlet configuration is a little different than the first blower we had. We quickly ordered up more 4.00" aluminum polished tubing so that we can get the inlet side back together.


Gauges:



We installed two Autometer carbon fiber gauge cups on the dash, and installed an Autometer boost gauge and an AEM air/fuel ratio gauge.





We got the new 8 rib drive pulley assembly (thanks Left Coast!) and everything aligned perfectly.



It is back to the dyno now!


Update: 5/28/09



We had been told by Left Coast that we may encounter problems with the truck throttle body, and they were right. The truck throttle body has a tendency to close shut under boost, and when it happened to us, the blower belt came off and took the water pump pulley with it! We haven't ever had this happen before, Dustin said they had it happen once at Lingenfelters on an ASA motor.



We have an LS2 throttle body from Cody's 2006 GTO at the shop that is no longer being used, and we had it machined to work with the truck Magnacharger kit. The LS2 throttle body's don't have the tendency to go shut like the truck throttle body's do. Now we're desperately waiting on a new water pump to arrive so we can get this Hummer back on the dyno!


We're encountering belt slippage, so we ordered a slightly smaller belt that we're going to try to get on. We can't lock up the torque converter on the dyno, the rwhp numbers would be a higher if we could lock the converter up.



This dyno sheet shows the amount of time into the dyno run where the torque absolutely goes crazy. This Hummer is going to be a real tire frier!


6/10/09



We managed to install a Napa 25 0081074 belt and we put the Hummer back on the dyno, but we're still getting belt slippage. We have a different type of belt on order that we're going to try, to see if we can eliminate this problem.



We removed the blower pulley and sandblasted the finish off the pulley, where the belt makes contact with it. We are hoping this will eliminate some of our belt slippage problems. 

6/19/09

  

We ordered a Dayco poly cog 80.0 belt on and we're not seeing belt slippage until approx 5600 rpm or so. It's a hot and humid day here today, not ideal conditions for making a lot of dyno power, but the dyno graph looks much better.

http://www.youtube.com/watch?v=_Py8fcjeqnc
Video from inside the Hummer watching the speedometer during acceleration.
 
http://www.youtube.com/watch?v=K9VuE4LS3Ac
Video of the Hummer launching from an idle.

http://www.youtube.com/watch?v=ZydN6b6h3bk
Video of the Hummer at the dragstrip.
it was very hot, the DA was 3850 plus the dragstrip was greasy, but the Hummer still did a 2.08 60 ft time and a 14.23 in the 1/4 mile. This was after driving the Hummer 75 miles to the track, so the engine was good and hot. With cooler temperatures this Hummer should get into the twelves in the 1/4 mile.



We ordered up a phenolic blower spacer to isolate the supercharger from the engine heat. This spacer is made by a guy who came up with the idea for his Magnacharger powered truck.









We epoxied these spacers into the blower to fit the phenolic spacer.



Here is a good look at how the spacer fits, and isolates the blower from the manifold.



Here is a good view of the cog drive assembly on the rear of the blower.



The blower is ready to be reinstalled in this picture.



We're currently at 601 rwhp and 719 ft lbs of torque, this is with a larger 3.2 pulley and the boost is down to 11.9 psi. 
Not bad at all, the spacer really helped!



Wow!  We had a sneaky suspicion the airbox might be restricting airflow, so we removed the top of the airbox. Boost jumped up from 11.9 to 12.6, and horsepower increased from 601 rwhp to 645 rwhp! The above dyno graph has both runs overlayed on them, so you can see the differences between having the airbox enclosed and open. What really surprised us was that the power always nose dived off at approx 5800 rpm, now it just levels off. When the airbox is this restrictive, it places a much larger load on the blower, which can in turn cause belt slippage. We have seen this in the past when we use a standard size ATI ProCharger air filter, when we start cranking up the boost.

Next we are going to reinstall the smaller 3.0 blower pulley that we initially had on the blower.



With the smaller 3.00 blower pulley back on we encountered massive belt slippage at approx 3300 rpm, as you can see on the above overlayed graph.  Even with the blower making a lot more boost prior to the belt slippage, the horsepower and torque were nearly identical to what it produced with the larger 3.20 blower pulley. It appears we have found the maximum efficiency range of our combination. The blower belt is now toasted, it slipped so bad it was smoking.



Here is the factory airbox that we had previously installed a high flow air filter. This is how we ran it when we picked up the additional horsepower.



This is where the air is picked up from to get into the airbox.



The throttle body we are using is a 90 mm ported unit designed for the '05-'06 GTO , so we're pretty confident it is large enough. We're going to try a Lingenfelter 100mm mass airflow sensor to see if we pick up any additional power.



Here is Lingenfelter's 4.00 MAF. We're using it with 4.00" tubing, so it will be interesting to see what it does for us.



We found out that Lingenfelter's did not have tables for this maf set up for programming with an '08 Hummer. We were fortunate to have Lingenfelter's head honcho Graham Behan, supply us with the necessary info by the end of the day.



Bingo! The Lingenfelter MAF made a huge difference! 672 rwhp and 752 ft lbs of torque! Rwhp with from 645 to 672 with just the addition of the larger maf. Kudos to Khalid (from the business over is Saudi) to suggest we try a larger maf!

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