First look at the new Procharger

mybajaboat.com

I purchased the Procharger 496HO install kit and will operate at 3.5lbs of boost. I want to go faster, but idle and slow cruising is important to me. The kit can be upgraded at any time to 5lbs by changing pulleys, and adding a modified fuel system. I would like to start by saying, there is no way I would try to install this kit by myself. Gary Radtke, former APBA Offshore mechanic, now working at Marine Center, did a GREAT job with all the wrench work. In the 275, it is just too tight to try without removing the engine first. The kit is very complete, but as stated in the owners manual, you must allow for variations in your individual application/engine. This means changing a couple of fittings, hoses, etc. Once installed, it's a clean looking product, almost stealth like, especially on the 496. One concern I have is how easy it will be to change the Procharger's oil. The drain screw can be reached, but is very tight and can't be "seen" with my application. A low sided baking pan should serve well as an oil catch. We had to close the plug gap and use a step colder sparkplug to solve a detonation and missfire problem we discovered after some WOT testing on the dyno. It is very hard to properly adjust the fuel pressure and complete a full throttle shutdown to examine the plugs if not using a dyno. (Imagine trying to do so on the water while underway!) Luckily, these problems were solved before getting on the lake! A fuel pressure gauge is a MUST! I had one installed to match the other gauges immediately. The only thing left to do is figure out which prop runs best! So far, I am running a factory 28 pitch Bravo I 4 blade. (Stock the boat came with a 23 pitch Mirage Plus 3 blade). In stock format the boat ran about 64mph on GPS, 68mph on the speedo. Now, it runs 72mph on GPS, and 76mph on the speedo! I believe I still can get a little more speed out of the boat after I lab finish the prop because I am only running at 4550-4600 rpm with the factory 28 pitch. The engine should run 4800-4900 rpm at wide open throttle. Lab finishing will give me about 300 more rpm's and a couple of mph's. I'll keep you posted!
	First look at the new Procharger. For looks, we had it painted Mercury Racing Blue.
	The Outlet and ID Tag.
	The Inlet Vanes.
	The Intercooler designed especially for the 496 HO. (Before Paint)
	All the parts as shipped. (Christmas in May!)
	First the engine had to come out. So off comes the outdrive and exhaust.
	Engines out.
	Rear of engine.
	Closeup of the rest of the outdrive.
	Future site of Procharger!
	Future site of Procharger's new Fuel Regulator. (Under full boost, 62-65 lbs fuel pressure is required.)
	Procharger pulley installed.
	The Latham Steering Reservoir will have to be moved.
	Custom fabricated bracket for reservoir.
	Close up of Procharger regulator.
	Had to modify routing of fuel line. The red engine stand would be the motor mount in the boat.
	Fuel Regulator is installed with cleaner lines away from motor mount.
	The stock power steering pump is replaced with Procharger's. (Stock is on the left.) The reservoir fitting must be changed for clearance.
	Procharger installed. Tee fitting for intercooler water hose is sloppy.
	Replaced water inlet tee fitting with 90 for cleaner look and fit.
	Procharger doesn't accommodate the pcv breather hose well, so we made one.
	Intercooler is installed. We had to move the exchanger over slightly to make clearance for the intercooler.
	The kit's intercooler fitting also had to be replaced with a 90 and "modified" to clear the oil filter.
	Back of the engine with the cover on. The extra hose is the intercooler discharge.
	Ready to put back in the boat!
	Procharger, Intercooler, and Reservoir in boat. (Mercury Racing Blue)
	View of Intercooler cover. Made from aluminum, looks cool! Probably will powdercoat this winter.
	Close up of dress cover for intercooler.
	Regulator top view in boat.
	VERY TIGHT FIT! Had to trim plastic engine cover to clear inlet hose and grease irk on hatch actuator.
	Procharger's oil fill cap doesn't even fit! (Stock is on the left.)
	Our custom modified oil cap accommodates the vent tube just fine!
	Intercooler discharge hose and fitting.
	Custom Latham Steering with incorporated drive shower cap before water source.
	Intercooler discharge becomes the water source for the drive shower.
	"Snaked" drive shower hose won't kink with outdrive in trailer position.
	Close up of shower hose / intercooler dump.