My brother has always wanted another scout 800 so I volunteered to build a better one on a budget. The scout we chose is a 1966 scout 800 with the 4 cylinder, t98 4 speed transmission and t18 transfer case. The motor is out and I have a soon ready to go in 1983 Mercedes 300D om617 5 cylinder turbo diesel. I was going to adapt a 5 speed tranny to the mercedes engine but the scout 2 dana 44 axles that are going under it are 3.07 gears and keeping this transmission will be cheaper and it will hopefully fit right back in the same spot once it's bolted to the mercedes. Another thing I like is the pilot bearing in the flywheel, it saves me some adaptation trouble. Should be interesting building the adapter plate. The rear axle will have scout 2 springs with a spring over and the front axle will be converted to coils and power steering. I have an Eaton m90 supercharger that I will side mount on the diesel engine and I will build a custom header with 3" exhaust. Fox shocks go on depending on how much axle articulation I will end up with. I should be able to get the scout and my supercharged diesel bronco done before May and get them on the dyno. I was going to start a bronco thread but I have it going over at FTE so I'll just post a link.

Supercharged Smok'n Bronco Build Thread - Ford Truck Enthusiasts Forums

Some project pics.

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Figured I'd post some more pics. I'm waiting on a custom aluminum flywheel to be made before I can start getting everything together. I've decided to go with the Eaton m45 supercharger for better efficiency and ease of mounting. I know I know, superchargers are not efficient.

The forum I originally had this on keeps having problems and I'm tired of it, so I'm keeping the build over here.

 

Interesting.

 

Aluminum flywheel? I'm not an engineer, and I don't play one on TV, but, that seems weird. Are they common?

 

Some Mustangs, Hondas and Nissans have aftermarket aluminum flywheels. I haven't heard of many custom made flywheels like what I'm doing but they are out there. All the shops I have talked to refuse to mess with a cast flywheel, can't say I blame them. If this flywheel were steel I'd just have it welded and re drilled. Seems most flywheels come off because of massive power and or rpm or because of old stretched bolts. Funny thing, most mercedes intended adapter kits require welding and re drilling a cast flywheel. Seems like a big liability issue to me but when I contacted one company they didn't understand the problem. At any rate, aluminum makes me feel better than welded cast iron. The flywheel will be pretty thick so I think it will be plenty strong enough for this motor. I hammered off the ring that way the cast iron teeth can be pressed on the aluminum flywheel after it's done. I was going to have a steel friction plate added to it but that can wait. Machining it for the friction plate down the road will take care of the wear. I don't know the cost of having a flywheel machined yet, should be interesting.

 

Cool build with the supercharger! Look forward to the outcome.

A cheaper possibility may be to make/buy a crank shaft adaptor that bolts to the MB crank and in turn accepts the bolts from the flywheel of your choice. Also seen a few flywheels that are a close fit to the MB crank where they then drill out new flywheel bolt holes to match the MB crank bolt pattern.

 

I was actually considering the adapter. But what I have decided to do is like you said, get a flywheel with a closer bolt pattern. In this case I bought a performance steel chevy 153 tooth flywheel that can be safely drilled or welded. I discovered that the t-98 4 speed won't work as easily as I thought because my bell housing from the t-90 won't work with it. I could use the t-90 but I'm not that enthused about using a 3 speed. I also looked at the cost of a new scout clutch pushing near $500, ouch. That's not including new master slave cylinders. I thought well, I have the chevy flywheel now... So I'm back to working out adapting a NV3500 to the mercedes. Shouldn't be to difficult. I found a good tranny out of a 2001 s10 and an np208 passenger drop t case out of a full size chevy. I'll do my best to change the np208 to a fixed yoke but I'll make it work either way. I'll be into the t case and transmission about $250 and and at about $400 after getting the clutch figured out. That will depend on the condition of the system in the s10, I might get everything from it. Because of the supercharger, an overdrive gear with this tall gearing might be more feasible because of the torque curve change and the option would be nice to have. With a bypass installed I want to test to see what happens to the egt's and gas mileage with an rpm drop, and just like the plan with my bronco, see what happens at different levels of bypass to find a possible cruising sweet spot. My theory is that the problems associated with running constant boost while cruising will be overcome by a beneficial drop in rpm. Running down the highway at 1600 rpm will definitely save on fuel if the motor isn't being lugged. It will all come down to how the motor is affected by the supercharger and header. Right now the hold up is the flywheel being worked on. In this area there are only a few shops that I trust to do it right and this one has priority in the industrial sector and not in little projects like mine.

 

Are you planning on turbo-supercharging, or are you going to remove the turbo? If you are turbo-supercharging, what plans do you have to get extra fuel to go with the extra boost?.
The MB shoud be a good match for the little scout I am curious to see how the MB can handle the 3.07 axles. Do you have a final drive ratio yet?

 

No compound setup for this one. The scout and my bronco are supercharger only projects. That would be fun
though.... I'm thinking of another project again.
With the m45 by itself and the intercooler setup off of the Kompressor I should be in the stock boost range with some adjustability. My plan on this one is to change it's power curve rather than go for an overall gain. With the way the ALDA works, fuel should be regulated according to the additional boost at a lower rpm, otherwise I'll just remove the ALDA altogether. Should make for some fun MPG tests. What better way to test mileage than to install the motor in a brick shaped vehicle? It's even the color of a brick.

High range

(1) 10.71
(2) 6.63
(3) 4.30
(4) 3.07
(5) 2.39

Low range

(1) 28.07
(2) 17.37
(3) 11.26
(4) 8.04
(5) 6.27

I'll be going 70 at just under 1800 rpm. Of coarse overdrive is optional. I wish first was lower but it will be better than the t-90, though the t98 has that low first gear. He can always do something with the t case at a later date. I would like to install a doubler on it while I'm messing with cases, but that will depend on funds. I have to be prepared to pay for some expensive machining to get my bronco done. The way that's going the work on these might stretch well into the summer, so maybe I will have time to get a better t case figured out. I could run the np205 but the shifter rod is in the way of the tranny. I haven't found out yet if the 203 will bolt up or interfere. I would really like to get rid of the slip yoke before modifying the drive lines, so I'm definitely going to run through options and see if I can do a t case combo before resorting to mixing parts or buying a slip yoke delete for a t case that might be switched out later.

 

reading your post again; made me think about trying to build an adjustable speed v-drive pulley system. So you could have an adjustable speed blower. I thought that way you could really fine tune the manifold pressure and also perhaps reduce the HP required to drive the blower at the exact rpm/MP you wanted for economical cruise power. Some of the old RaJay turbos I worked on had manual adjustable waste gates, so you could dial in your manifold pressure after you reached cruise altitude

my stock xj auto is running about 2200rpm at 70. I have not been able to get the MB powered xj going that fast yet, because of the deathwobble plus the MBxj odometer is not working yet so I don't have mpg's. I think the other guys are getting in the mid 20's I am not sure what the sweet spot is on the benz, but it is a pretty high revving motor. The guys with the Kubota's are running 1800 rpm at hi-way speed I think, but they are paying over $1000 for their engines, and the MB's are free or almost free after you scrap the body's
Well your project sounds fun. The header should be fun. I had a good time modifying my MB's downpipe and collector