The world’s most advanced variable-vane turbochargers are currently available in two forms: the 53-Series and the 66-Series. Neither of which require a wastegate, boost controller, or turbo timer.


Please visit the following pages before you continue:

Aerocharger Technology Explained

Aerocharger Operating Guidelines

Aerocharger Service and Repairs

Aerocharger Frequently Asked Questions

Aerocharger Mock-Up Turbos:
We have mock-up turbochargers available for fabricating your custom turbo system and dialing in your Aerocharger's orientation. This is a critical step in any custom Aerocharger turbo systems as a finished Aerocharger cannot be reoriented without the proper precision equipment. These mock-up turbos have no internal parts and can be adjusted in any way necessary, even the controller location. Once your turbo system is complete and you have your mock-up turbo finalized, you may return it to us and we will build your Aerocharger to those specifications. Use the provided charts and calculator to configure your Aerocharger and determine which is best for your application. To purchase a mock-up Aerocharger please call 913.829.3400

Understanding Compressor Maps

Generally compressor maps are created in a lab under ideal conditions. Most installations will include an air cleaner, muffler, and adequate plumbing. Your actual results may differ slightly, but these maps serve as an excellent starting point. By answering a few questions and inputting several values into the table we can determine the right trim size for the compressor and turbine.

Understanding Surge Line

The Aerocharger has a very soft surge, which means that turbo flutter is mild and it is capable of quickly recovering. However it is still best to understand what surge is and how it affects power delivery.

Surge is most commonly experienced when one of two situations exist. The first and most damaging is surge underload. This can be an indication that your compressor is too large for your application. Surge is also commonly experienced when the throttle is quickly closed after boosting. This occurs because mass flow is drastically reduced as the throttle is closed, but the turbo is still spinning and generating boost. This immediately drives the operating point to the far left of the compressor map, right into the surge line. The surge line is left hand boundary of the compressor maps below. Operating to the left of this line represents a region of flow instability. On a conventional turbocharger this region is characterized by mild flutter to wildly fluctuating boost and “barking” from the compressor.

Surge will dissipate once the turbo speed finally slows enough to reduce the boost and move the operating point back into the stable region. Aerocharger surge is hardly noticeable, where as conventional turbo surge is hard. A hard surge is very noticeable along with a sudden flutter of power. This is less than desirable and potentially disastrous. One example would be on a motorcycle when trying to roll into the throttle for a fast exit out of a hard turn.

Adjusting the vanes

Variable-vanes create optimum geometry for exhaust flows at any given RPM. This is done by changing the angle of the vanes within the turbine housing. The Aerocharger provides a unique adjustment which gives the user ability to adjust when the vanes move and how boost reacts to the engine. By closing the vanes boost is allowed to build quicker and maximum boost is made lower in the power band. Opening the vanes slows boost and raises the power band for more power up top. A PDF document is provided to show how to adjust boost and vane angle:

Turbo Controller/Vane Adjustment Manual