Thanks CosmicX

I've been on the fence about the modification, but think I'm still going to go "cautiously" ahead.

Here is why.

The majority of those who experienced problems used a pulley which wasn't made to spec. In the case where the supercharger seized, it was the poor quality pulley (and possible user error with installing it). The pulley expanded when it got hot, and started slipping.

The other guy damaged his stock pulley in removal. The instructions posted on ASP Racing\'s site states

While there have been a few, who have successfully removed their pulley with a 3 jaw puller, there have been many more who have not. I have a plan to fashion a 6 jaw puller, to pull from both the back edge, and the inside front edge of the stock pulley. Twice the area of force spread out equally against the same amount of resistance. I think it will work, and will post my success (or failure) along with photos, when I perform the upgrade (I am waiting on my boost gauge, that will be installed prior to the pulley mod).

The problem with losing all boost was attributed to bad gas. Those who had experienced the problem had filled up with premium at "mom & pop" gas stations. After filling up with premium from a "name brand" corporate station the problem went away. Some have even reported this condition (later in the same thread) with their "stock pulley". This may be due in part to the higher compression, and some sort of narrower tolerance of octane.

Don't get me wrong, I understand your "cold feet", and I agree with you when it comes to the pulley size and the RPMs.

ASP Racing\'s pulley is 2.35", which is reported to turn the supercharger at 15,880 (damn close to Eaton's maximum tolerance of 16,000) at 6,000 RPMs.

This is where I feel a bit more at ease. I've got an automatic, and I don't think I've ever had the engine revs up that high. Even when merging onto our local beltline (with metered on-ramps) and jumping on the accelerator, it shifts between 5,000 and 5,500 RPMs. If anything, the highest revs are only for a couple seconds.

I don't plan to race my Xterra, but I do want more power when passing on Wisconsin's winding two lane roads where passing zones are usually shorter than football fields. I drive moderately, and am far from what most consider "hard" on my vehicle, (bought it primarily for towing and winter driving) so I think that combined with a strict maintenance schedule will see me through.

My first step will be the boost gauge, which is on back order for a couple of weeks. I won't fault your choice one way or the other. I will be sure to post my results.

Regards,
Spence