On my last Donny track session, I managed to break my new charger. Thankfully I was on the last drop of fuel for the day, so I didn't loose any track time. Not sure why the new charger failed so early, but it was the same problem as last time with the impeller snapping off the shaft. I sent it back to TTS as it was still under warranty and about a week later they told me Rotrex were happy to replace it. I asked TTS if they could replace it with a C38-91 instead of a C30-94, and they agreed. Now all I had to do was make it fit! - winter project time.
New C38-91 charger side by side with my original dead C30-94
Time to CAD a new bracket
Test fit of a 2d cardboard version of the bracket
The cardboard seemed to fit, so I made a wooden prototype at the local Fab Lab
The wooden version showed me I needed an extra 5mm to clear the fuel rail, but that otherwise it should all fit after a bit of cutting and bending!
I uploaded my CAD model to the protolabs website, and 3 days later a new bracket arrived. It fitted perfectly.
A couple more days bending, cutting and trimming and it was in!
Now I just need to run it in for 60miles and I can see what sort of boost I can get from the bigger charger.