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MEMBERS => MEMBER PROJECTS => Topic started by: denmah on October 24, 2007, 02:38:22 AM

Title: 06 636 turbo project
Post by: denmah on October 24, 2007, 02:38:22 AM: 110whp stock,
147whp on spray,

decided to do something new...

(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8614.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8615.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8617.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8618.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8619.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8621.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8624.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8625.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8629.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8632.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8634.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8636.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8640.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8642.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8643.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8646.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8648.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8655.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8662.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8683.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8685.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8688.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8694.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbohat/100_8698.jpg)
Title: Re: 06 636 turbo project
Post by: denmah on October 24, 2007, 02:38:55 AM: painted and hose clamped on!

(http://img.photobucket.com/albums/v479/denmah/1021071646a.jpg)
(http://img.photobucket.com/albums/v479/denmah/1021071646.jpg)
(http://img.photobucket.com/albums/v479/denmah/1021071453.jpg)
Title: Re: 06 636 turbo project
Post by: denmah on October 24, 2007, 02:40:05 AM: Well, while im waiting for the turbo and the scavenge pump to arrive, along with my flanges to get machined, I recieved my 45 degree bend so i can go around the cyl head nicely with a soft pipe to minimize scraping the rad and valve cover. I routed the vaccum lines the way i wanted to, so they are not such a mess, and 4 lines T fitting into one was really a boost blown off vaccum nightmare waiting to happen in my head. So I flipped most of the hoses together and zip tied them down, then i attached the factory speed density sensor, and left one open for my GM 2 Bar Map sensor, and one more on the end running to my boost gauge. Boost gauge! i had one laying around that is off +1psi so i decided its a freebie why not mount it for now and get a liquid filled one later, zip tied that nice and routed it up around the dash, drilled a nice little hole and fed one of the clap screws in and washer and nutted it down, it is mounted very very securely and looks great i think. Here are some pics of the stuff i did today.

(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8710.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8711.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8712.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8714.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8715.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8716.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8717.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8720.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8721.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbomisc1/100_8722.jpg)
Title: Re: 06 636 turbo project
Post by: denmah on October 27, 2007, 02:32:59 AM: got my mr turbo scavenge pump today

(http://img.photobucket.com/albums/v479/denmah/bike/100_8731.jpg)

and here is the fresh new turbo alongside my beat ass mock up turbo...

(http://img.photobucket.com/albums/v479/denmah/bike/100_8735.jpg)

i think you guys will like how small it is, ko3 off a VW 1.8t roughly 250hp turbo!
Title: Re: 06 636 turbo project
Post by: denmah on October 30, 2007, 03:26:45 PM: so it took a little while, but my flanges came in today!

(http://img.photobucket.com/albums/v479/denmah/1030071411.jpg)

(http://img.photobucket.com/albums/v479/denmah/1030071600.jpg)

hopefully i can get the hotside all done tonight, maybe even the DP.

i will have more time on the weekend, but there is a street car shootout coming up this sat, that me and my friend have to put his turbo mustang in.
Title: Re: 06 636 turbo project
Post by: Endless1000 on October 30, 2007, 03:32:38 PM: damn dude nice work man!!keep us updated
Title: Re: 06 636 turbo project
Post by: denmah on October 31, 2007, 11:36:22 PM: (http://img.photobucket.com/albums/v479/denmah/bike/flange.jpg)

welded the inlet pipe to the flange, pretty welds!

we made the log header, but its too long, i didnt even take pics of it.

we are gunna cut the header behind the connectors and actually bend them to collect a bit.

i think friday during the day more will get done.
Title: Re: 06 636 turbo project
Post by: denmah on November 03, 2007, 12:03:00 AM: (http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8749.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8750.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8751.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8753.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8754.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8755.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8758.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8759.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8760.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8761.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8762.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8764.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8765.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8766.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8767.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8768.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8769.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turboheader/100_8770.jpg)

http://www.youtube.com/watch?v=lQpcZY_CpzM
Title: Re: 06 636 turbo project
Post by: Busafied™ on November 05, 2007, 07:26:20 PM: It is coming along nicely :thumb:

Feels good doing it yourself doesn't it?

I been watching- few things you will change as you go, just keep picking away at it and you will find the boost you seek.

The K03 will spool quick be aware of that :wink:

My header is pieced together from the spigots/flanges of the stock header, and some mandrel bent tubing 1.75" in diamter larger then stock and any aftermarket I know, but I did that to minimize the restriction of airflow to the large frame turbo I chose..

GL,
Ron
Title: Re: 06 636 turbo project
Post by: denmah on November 05, 2007, 10:42:52 PM: thanks! i actually had it out for a spin today.

here is the finished intake piping. i made it realllly rich and you can tell when it goes into boost, the FI light comes on ahhaha

so i have to get a check valve for that or just live with it...

(http://img.photobucket.com/albums/v479/denmah/bike/intakepipe/100_8807.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/intakepipe/100_8808.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/intakepipe/100_8809.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/intakepipe/100_8810.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/intakepipe/100_8811.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/intakepipe/100_8812.jpg)

also i need to mount my oil pump higher or put in a check valve, oil sometimes runs out of the pan and bleeds into the turbo, makes it smoke when i start it.
Title: Re: 06 636 turbo project
Post by: denmah on November 05, 2007, 10:55:13 PM: http://youtube.com/watch?v=sJjkO_q6bxs
Title: Re: 06 636 turbo project
Post by: Busafied™ on November 06, 2007, 08:25:46 PM: HAHA kewl!

Have fun man, get it mapd on the dyno asap

Ron :thumb:
Title: Re: 06 636 turbo project
Post by: HOS on November 10, 2007, 05:11:09 AM: You have some major engineering skills there dude :thumb:

Do you do this kind of thing for a living ?

Not many decide to turbo a 6 !!!
Funnily enough I have a ZX6R project on the go :wink:
Nothing major, more a heavy duty cosmetic job. Prime goal to lower the bike about 3 to 4" !!! :shock:
Title: Re: 06 636 turbo project
Post by: denmah on November 13, 2007, 10:01:57 AM: blew up the turbo, i was told i didnt need an oil restrictor but i guess that was wrong haha.

made 80hp and 33ftlbs on the dyno, also got a nice missfire from the oil in the intake :(

new center section and oil restrictor on the way!
Title: Re: 06 636 turbo project
Post by: grecco on November 14, 2007, 09:42:58 PM: keep us posted.
:thumb:
Title: Re: 06 636 turbo project
Post by: denmah on November 18, 2007, 04:39:22 AM: i got the new turbo center section today!

i should be getting the oil restrictor soon and ill be ready to play
Title: Re: 06 636 turbo project
Post by: denmah on November 27, 2007, 10:28:05 PM: everything is ready to go, new turbo assembled and installed, piping all attached, 2 bar map isntalled, filter, some fresh oil, replaced my oil return lines with some much shorter stainless lines at your advice, so the pump can push easy.

just waiting on this restrictor they say should be in 2-3 days

pic of the stainless.
(http://img.photobucket.com/albums/v479/denmah/bike/1124072045.jpg)

im very excited to get this thing back out on the road.
Title: Re: 06 636 turbo project
Post by: denmah on December 01, 2007, 03:11:47 AM: all ready to get back on the dyno

turbo hitting 4psi, might need a boost controller for the dyno

(http://img.photobucket.com/albums/v479/denmah/100_9042.jpg)
Title: Re: 06 636 turbo project
Post by: denmah on January 03, 2008, 11:05:47 PM: couple things...

pinholed my radiator moving an intake pipe with the hoseclamp, bolt out towards the rad... doh!

the oil was backfeeding out of the pan into my turbo, doh!

my intake manilfold had a boost leak because my friend ground the welds off to make it look pretty, doh!

my turbo blew up because i didnt have an oil restrictor on it. (wich i already posted about)

so i got the pan and the radiator welded up and put her back together tonight and fired her up and took her for a spin. it was 12f out so she spun in 1st 2nd and 3rd. haha, but seems to be ok, gotta put the plastics on and save up some more cash and get this pig on the dyno ASAP!

(http://img.photobucket.com/albums/v479/denmah/bike/return/100_9070.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/return/100_9072.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/return/100_9073.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/return/100_9074.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/return/100_9075.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/return/100_9076.jpg)

12f testing mode!

(http://img.photobucket.com/albums/v479/denmah/bike/return/100_9077.jpg)
Title: Re: 06 636 turbo project
Post by: denmah on January 04, 2008, 11:36:25 PM: well i had it out again tonight guys, took out alot of fuel, only adding about 10% at 4psi where the gate is set right now, it had so much fuel in it before it was stumbling right before boost.

so i cleaned up the boost map, and took her for a rip, and damn, its 31 degrees out right now, dark, the roads are cold and my tire is shot, but she spun off 4th gear and got pretty squirrly, enough to scare me haha and i have brass balls.

right now im so happy with the progress i dont wanna break it so im setting up an appointment for thursday, its supposed to be a tad warmer and i wanna get her done ASAP.

i was worried i would want more like 8-12 psi, but after tonight i think 4 might be making enough power for a while.
Title: Re: 06 636 turbo project
Post by: denmah on January 05, 2008, 11:51:53 PM: heres some shots of the bike done today, rained as soon as i got of work, fuckers!

excuse the rough cuts around the wastegate, i couldent get in there right with the tinsnips and ill clean it up later with the rosebud.

(http://img.photobucket.com/albums/v479/denmah/bike/turbodone/0105081746.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbodone/0105081746a.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbodone/0105081747.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbodone/0105081817.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/turbodone/0105081817a.jpg)

dyno thursday
Title: Re: 06 636 turbo project
Post by: denmah on January 07, 2008, 01:21:05 AM: took her out for a spin today!

http://www.youtube.com/watch?v=um2oiMUsTPY
Title: Re: 06 636 turbo project
Post by: denmah on January 08, 2008, 04:14:07 PM: bueller
Title: Re: 06 636 turbo project
Post by: SPARKY1397R on January 08, 2008, 07:10:44 PM: cool :thumb:
Title: Re: 06 636 turbo project
Post by: KIRK_ADAMS on January 09, 2008, 06:33:31 AM: LQQKIN good.....
Title: Re: 06 636 turbo project
Post by: Mike-Nightrider on January 09, 2008, 11:57:20 AM: :thumb: good work
Title: Re: 06 636 turbo project
Post by: denmah on January 09, 2008, 06:14:01 PM: boost controller went on tonight.... bike really likes 6psi instead of 3, wow boy :vl:

dyno tomorrow, this was the last thing i wanted to straiten out before i went, boost + good!
Title: Re: 06 636 turbo project
Post by: denmah on January 09, 2008, 06:46:22 PM: my dad took the liberty to do some fine tuning to the lower plastics, while i installed and played with the boost controller.

(http://img.photobucket.com/albums/v479/denmah/bike/0109081933a.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/0109081933.jpg)
(http://img.photobucket.com/albums/v479/denmah/bike/0109081932.jpg)
Title: Re: 06 636 turbo project
Post by: denmah on January 10, 2008, 03:04:24 PM: VIDEO!
http://youtube.com/watch?v=CDTutyUJClc

oh yeah i went to dyno it today at scott powersports... and their dyno tech called off work. awesome for them to let me know, stupid of me not to call ahead and check, i went to ride it again, and their tech wasnt in either! i was like WTF! haha, finally called my friend there who is farther away and has a mustang dyno, even though i wanted dynojet numbers for accurate comparison, ill get a dynojet pull sometime then to check out the change after the bike is more dialed in.
Title: Re: 06 636 turbo project
Post by: kawi9 on January 14, 2008, 09:50:36 PM: Wow good job :thumb: What is your air fuel ratio on full throttle and full boost ? I saw about 12.8 :1 ? You don't fix the smoke problem when you start the bike ?
Title: Re: 06 636 turbo project
Post by: ATLbusa on January 15, 2008, 12:52:14 AM: Hey to give you a heads up, look close for exhaust leaks when you cut and twist those downtubes it changes the angle of the seating face of of the pipes. I know this because first turbo I had built back in 97 we used the muzzy header, and ended up with leaks around the gaskets due to this. Ohh and it was a kawi zx9 looking good.
Title: Re: 06 636 turbo project
Post by: pineygirl on January 15, 2008, 06:34:53 PM: Quote from: denmah on October 24, 2007, 02:38:55 AM
painted and hose clamped on!

(http://img.photobucket.com/albums/v479/denmah/1021071646a.jpg)
(http://img.photobucket.com/albums/v479/denmah/1021071646.jpg)
(http://img.photobucket.com/albums/v479/denmah/1021071453.jpg)

:shock: :shock:
Title: Re: 06 636 turbo project
Post by: Smokin Ya on February 06, 2008, 08:58:38 PM: NICE WORK!! :D :thumb:
Title: Re: 06 636 turbo project
Post by: denmah on February 06, 2008, 09:34:11 PM: all done really, did better than i expected, i gained 26hp on just 4psi of boost.

108 baseline and 135rwhp on just 4psi

(http://img.photobucket.com/albums/v479/denmah/bike/636t.jpg)

just picked up a nice trailer for 300 bones!
(http://img.photobucket.com/albums/v479/denmah/bike/DSCF0006.jpg)
Title: Re: 06 636 turbo project
Post by: kawi9 on February 06, 2008, 11:26:20 PM: Nice. The number are better than the first time dyno :thumb: How many boost do you will run next time ?