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MEMBERS => MEMBER PROJECTS => Topic started by: dtechnologies on April 11, 2005, 07:43:24 PM

Title: The Frankenbusa Saga. Holy crap I'm still here!
Post by: dtechnologies on April 11, 2005, 07:43:24 PM

It's killing me to see others ride while I toil in the garage. But this past weekend I made some real progress. I managed to remove the engine, install my high pressure oil regulator, Terry McIntosh special modded oil pan, oil feed and return fittings, Muzzy oil cooler bypass kit, carpenter racing springs, and my .080 base spacer.

Here you can see the oil pan, fittings, and bypass kit. Having everything match blue was an accident. Terry McIntosh is a genius. The oil pan is a work of art. The return fitting is a regular bulkhead fitting. I cut most of the threads off on the inside and chamfered the nut to hold and o-ring.

(http://members.shaw.ca/dtechnologies/pics/webbusa004.jpg)

Here's a look at the engine stand I built...surprisingly easy.

(http://members.shaw.ca/dtechnologies/pics/webbusa014.jpg)

Here's the fuel plate I built from some scrap steel and some hose barb fittings I had laying around. Once I painted it black, it looked awesome. Fuel pump, regulator and fuel sender...they all just take up space that could be used for fuel!

(http://members.shaw.ca/dtechnologies/pics/webbusa010.jpg)

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: SPEED KING on April 12, 2005, 12:21:17 AM

Gettin there.. :D

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: nemsis on April 12, 2005, 02:28:27 AM

looking good

you did remember to take out the restrictor plug behind the oil filter right.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on April 12, 2005, 04:14:08 PM

I was under the impression that the restrictor only had to come out if one blocks the cooler ports off like on a ghetto kit.

Correct me if I'm wrong...please.

Thanks,

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on April 12, 2005, 11:03:18 PM

I installed the new coil today. coil on plug is just extra wires and extra programming so I'm doing with an MSD blaster coil.

(http://members.shaw.ca/dtechnologies/pics/busacoil.jpg)

The picture's short a few megapixels...damn camera phone.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: nemsis on April 13, 2005, 02:25:55 AM

Quote from: dtechnologies

I was under the impression that the restrictor only had to come out if one blocks the cooler ports off like on a ghetto kit.

Correct me if I'm wrong...please.

Thanks,

I got the same Muzzy jumper line and I took my plug out, it can't hurt having it out

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on April 14, 2005, 05:57:24 PM

I picked up the flange I had water jet cut for the headers.

I'll post a picture later.

I'll never buy a retail flange again!

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on April 15, 2005, 08:21:46 PM

(http://members.shaw.ca/dtechnologies/pics/webbusaflange.jpg)

Title: Frankenbusa has spark!
Post by: dtechnologies on May 01, 2005, 08:46:14 PM

I finally got my EDIS connectors and boots from Magnecor (whom I highly recommend for ignition products).

I had the coil mounted previously but I finally have the wires made and installed.

I was able to re-use the seals from the original coil sticks by sliding over top of the MSD Pro racing boots...a near perfect fit.

(http://members.shaw.ca/dtechnologies/pics/busacoil.jpg)
(http://members.shaw.ca/dtechnologies/pics/webbusasparkwires.jpg)

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: nemsis on May 01, 2005, 09:36:58 PM

looking good :thumb:

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: Busafied™ on May 04, 2005, 07:19:26 AM

Looking good dave!
8)

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: busa2001 on May 04, 2005, 12:36:56 PM

post some more pic.. :D

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 04, 2005, 07:05:31 PM

I'll have more pics on Sunday...hopefully I can get a lot of work done this weekend.

(http://members.shaw.ca/dtechnologies/pics/frankenbusa.jpg)

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 09, 2005, 12:39:25 AM

I finally managed to plumb the fuel system. It's a bit ugly because I'm using a lot of brass hose barb fittings to save money.

(http://members.shaw.ca/dtechnologies/pics/webfuel.jpg)
(http://members.shaw.ca/dtechnologies/pics/webfuel2.jpg)

The fuel pressure gauge is temporary to test and make sure it builds pressure. The gauge will be mounted up front in the end.

One thing you can't see real well are the BMW quick disconnect fittings that go between the fuel system and the tank. O-ring seal and they block the line when disconnected...worth every penny and then some.

I started building the headers today...slow and painful but I figured out a few shortcuts that I hope will make for an interesting design (it's different than anything I've seen before). I should have those done in the next day or so.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: THEMOTORHEAD on May 09, 2005, 06:40:55 AM

I WOULD NOT RUN THAT CUT DOWN STOCK PAN

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 09, 2005, 07:24:43 AM

I'm sure you wouldn't do a lot of the things I'm doing :lol:

I trust Terry McIntosh. He's done many of these pans over the years with no complaints.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 11, 2005, 10:50:00 PM

I mocked the turbo last night and I've come up with 2 problems.

(http://members.shaw.ca/dtechnologies/pics/webturbusa.jpg)

1: I'm pretty sure the internal wastegate that came with my turbo is shit or siezed or both.
2: The turbo doesn't fit unless I take the wastegate off anyhow.

Anybody know (Motorhead even?) know where I can get an inexpensive external wastegate?

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 15, 2005, 10:32:38 PM

Finally got the headers welded together. Need some cleaning up still but the turbo is mounted.

(http://members.shaw.ca/dtechnologies/pics/webturbo1.jpg)

Just have to find a wastegate now.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: cstraubs1 on May 16, 2005, 06:38:10 AM

Quote from: dtechnologies

I'm sure you wouldn't do a lot of the things I'm doing :lol:

I trust Terry McIntosh. He's done many of these pans over the years with no complaints.

Its not about the quality of the work/job. People have had crank/rod bearing problems promoted by the short pan. Me included....

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 16, 2005, 08:14:05 PM

Until somebody can give me a convincing explanation as to why shortening the pan will screw my bearings, I'll be confident that the cut pan will work.

I welcome any debate...I'm all for it. I'm just not the type to not do something just because somebody told me I shouldn't...what a boring life I'd have if I were like that :twisted:

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: cstraubs1 on May 16, 2005, 08:55:55 PM

Look at the side profile of your pan....see the slope in the rear?
When you launch hard,or wheelie it ramps the oil up and away from your oil pickup. So,when you shorten the bottom of the pan,you have even less oil there for the pickup...If you don't drag race,launch real hard frequently,or wheelie...then you probably won't have a problem...but whats the use of having a turbo??? 8)

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 16, 2005, 09:53:15 PM

I've heard that argument before...and I can see the logic in it...but

When I think about that scenario, this is what I think of...and these are the things I considered before deciding to go with a cut pan:

-The slope is there wether the pan is cut or not.
-The oil is very high in the engine in relation to the pickup. If you don't count wheelies (I don't wheelie), the oil has to be at a rediculous angle before the pickup is sucking air.
-When oil moves backwards in the pan (like when under hard acceleration), the slope at the back of the pan and the low nature of the pan keep oil forward because the total volume is less inside the pan. Take 2 engines, one with a stock pan and one with a cut pan. Tilt both rearward, the oil in the engine with the cut pan will be closer to the pickup (until the oil drains into the tranny anyhow).
-I've seen guys wheelie Hayabusa's and GSXRs with stock oil pans at nearly 12 o'clock for multiple city blocks without spinning bearings.

mind you, Motorhead has more Hayabusa experience in his little finger than I'll ever have :?

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: Adrnlnjunky on May 17, 2005, 08:55:53 AM

It's a losing battle straubies.

Work looks good so far, Dave. Good luck with it.

Just expect an, "I told you so" when the motor goes south.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: cstraubs1 on May 17, 2005, 06:24:32 PM

No biggie bro....just giving you a heads up.....project looks good!!! 8)

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on May 17, 2005, 07:21:37 PM

cstraubs1,

I'll take it easy on the 60' times to start just in case...shouldn't be hard. I have the reflexes of a hibernating grizzly bear. :lol:

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: cstraubs1 on May 18, 2005, 06:39:22 AM

Unfortunetly,I know exactly what your talking about.... :(

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on June 05, 2005, 10:41:04 AM

You haven't seen any updates on this project because I went and managed to twist my spine somehow (or so my chiropractor tells me).

Good news is that work has begun here at home on my custom ECU side of the project.

I've been able to verify that I'll be able to use it (as long as I can get the software right) to do the following:

- Fire Injectors
- Trigger coils
- Trigger water injection (if implemented)
- Operate the fuel pump
- Operate the cooling fan
- Operate the airshifter (upshift at x rpm)
- Control boost (the mechanical side of this is still in the air. At the very least it will be a 2 stage boost control switched by the ECU).
- Interface with gear position sensor...less boost in lower gears?
- Wheelie control. Reduce boost when wheel is in the air
- Wide band O2 sensor interface.

In my configuring and brainstorming, I've hit a bit of an impass. The crank trigger for my '01 has 8 equal teeth...this is proving near impossible to implement with the software I'm using. Anybody know where I can get a 24-1 tooth stator like on newer (2003+) models without breaking the bank or feeding the dealerships?

I'm also having difficulty figuring out the position of the sensors (crank and cam) in relation to the teeth...it's hard to measure the offset in degree's when the sensor is mounted to the cover. It seems even Autronic or Motec units don't like the original sensor configuration so I haven't found much help that way either.

I'm hoping to get back into the garage this week so I can make the oil lines and start making brackets to mount the ECU, intercooler, and start work fabricating the plenum.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on June 05, 2005, 10:42:18 AM

You haven't seen any updates on this project because I went and managed to twist my spine somehow (or so my chiropractor tells me).

Good news is that work has begun here at home on my custom ECU side of the project.

I've been able to verify that I'll be able to use it (as long as I can get the software right) to do the following:

- Fire Injectors
- Trigger coils
- Trigger water injection (if implemented)
- Operate the fuel pump
- Operate the cooling fan
- Operate the airshifter (upshift at x rpm)
- Control boost (the mechanical side of this is still in the air. At the very least it will be a 2 stage boost control switched by the ECU).
- Interface with gear position sensor...less boost in lower gears?
- Wheelie control. Reduce boost when wheel is in the air
- Wide band O2 sensor interface.

In my configuring and brainstorming, I've hit a bit of an impass. The crank trigger for my '01 has 8 equal teeth...this is proving near impossible to implement with the software I'm using. Anybody know where I can get a 24-1 tooth stator like on newer (2003+) models without breaking the bank or feeding the evil devilworshiping dealerships?

I'm also having difficulty figuring out the position of the sensors (crank and cam) in relation to the teeth...it's hard to measure the offset in degree's when the sensor is mounted to the cover. It seems even Autronic or Motec units don't like the original sensor configuration so I haven't found much help that way either.

I'm hoping to get back into the garage this week so I can make the oil lines and start making brackets to mount the ECU, intercooler, and start work fabricating the plenum.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on June 05, 2005, 10:51:01 AM

You haven't seen any updates on this project because I went and managed to twist my spine somehow (or so my chiropractor tells me).

Good news is that work has begun here at home on my custom ECU side of the project.

I've been able to verify that I'll be able to use it (as long as I can get the software right) to do the following:

- Fire Injectors
- Trigger coils
- Trigger water injection (if implemented)
- Operate the fuel pump
- Operate the cooling fan
- Operate the airshifter (upshift at x rpm)
- Control boost (the mechanical side of this is still in the air. At the very least it will be a 2 stage boost control switched by the ECU).
- Interface with gear position sensor...less boost in lower gears?
- Wheelie control. Reduce boost when wheel is in the air
- Wide band O2 sensor interface.

In my configuring and brainstorming, I've hit a bit of an impass. The crank trigger for my '01 has 8 equal teeth...this is proving near impossible to implement with the software I'm using. Anybody know where I can get a 24-1 tooth stator like on newer (2003+) models without breaking the bank or feeding the evil devilworshiping dealerships?

I'm also having difficulty figuring out the position of the sensors (crank and cam) in relation to the teeth...it's hard to measure the offset in degree's when the sensor is mounted to the cover. It seems even Autronic or Motec units don't like the original sensor configuration so I haven't found much help that way either.

I'm hoping to get back into the garage this week so I can make the oil lines and start making brackets to mount the ECU, intercooler, and start work fabricating the plenum.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on June 24, 2005, 07:43:43 PM

Considering the ghetto nature of my entire project, I didn't want to buy a new wastegate. However I was unable to find an inexpensive Tial gate used...I guess they're so good nobody is getting rid of them.

I managed to find a wastegate for just $130 bucks from a guy who does salvage for euro stuff. It's from an older Audi 5000 quattro but it's rebuilt with a new diaphram and looks practically new for all intents and purposes...it's hard to believe it was ever installed in something(I'll post a picture when I get a chance).

I've spoken to Audi guys at an internet forum and this wastegate comes stock with a 10# spring and has been known to last over 300,000km in daily drivers without failing. Bigger and heavier than a Tial by a longshot but at this point in the game looks don't mean much.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on July 07, 2005, 09:09:45 PM

I finally got the flanges cut for the wastegate and dump.

I'm going with a rebuilt wastegate off of an Audi. It's big, it's proven reliable, it's heavy, ... and it's already got a 10# spring!

I can tell already that fitting it in is going to be a trick. straight off the side of the header, it will still stick out past the frame. I'm going to run a 2" pipe with a 'more than 90' degree bend out of the back of the headers where there's just enough room to cut out a 2" hole.

It's going to join up with the 2.5" dump so closely that I'm not sure how I'm going to get bolts in to hold the wastegate outlet flange to the wastegate. I may end up turning the wastegate so the outlet is pointing more forward and then join them up with a bent section of 1.5" tube instead of a straight piece.

The plan is to run the 2.5" dump close enough to the engine that if I lay the bike down, the frame sliders will take the brunt of it. I don't want to loose the ceramic powder coating I'm going to have put on when I'm done.

I'm also considering welding an ear onto the dump so that I can bolt it to the front right engine stand mount...just for a bit of insurance.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: Busafied™ on July 07, 2005, 10:25:12 PM

Quote

The plan is to run the 2.5" dump close enough to the engine that if I lay the bike down, the frame sliders will take the brunt of it. I don't want to loose the ceramic powder coating I'm going to have put on when I'm done.

I'm also considering welding an ear onto the dump so that I can bolt it to the front right engine stand mount...just for a bit of insurance.

Sounds like a Trick idea to me ;-)

My 50mm was a b!tch to mount LMAO!

think yours sticks out any further LOL NOT!

not much a choice with a bigass 50mm Gate, whos Springs are larger then the entire height of a Tial 35mm lol

(http://busafied.com/boostafied/boosty.jpg)

Good Luck Man!

Ron

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: crazybill on July 09, 2005, 09:17:41 AM

i like the msd coil setup . if i had room for one i wouldnt mind having one . back in the day when i ran one on mt car it wasnt intended for use on the street (somthing about the coil overheating its self ?) i assume that issue was left back in the day ?

looks good so far , good luck with the rest !

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on July 09, 2005, 10:55:13 PM

Today I fabbed the dump pipe and started to mount the wastegate. And I remembered my camera! (though it looks from the date stamps that I forgot something else).

Instead of running twin dump pipes, I connected the outlet of the wastegate directly to the dump just after it leaves the turbo...the radiator hides the ugly pretty well :lol:

I hooked the bike up to the lift and leaned it over to the right to check for clearance on the dump pipe. I can't believe how far the bike leans before the pegs touch even though I've lowered it so much. No wonder I never dragged the pegs!

I've replaced the header bolts with studs. Much to my surprise, I was able to reuse 5 of the original bolts to mount the turbine outlet flange to the turbo and the other 3 fit the outlet of the wastegate perfectly.

(http://members.shaw.ca/dtechnologies/pics/webbusadump.jpg)
There's something satisfying about a big fat dump.

(http://members.shaw.ca/dtechnologies/pics/webbusadave.jpg)
A rare picture of me.

(http://members.shaw.ca/dtechnologies/pics/webbusaairfilter.jpg)
The 3" adapter was surprisingly easy to make out of some aluminum tube and plate...the bolts for this were recycled too...don't remember what part of the bike I took them off of.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: SuperGrizz on July 13, 2005, 01:28:15 AM

Man, I hope this bike sets records when you're done, given all the work you've put in. Any cost estimates to date?

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on July 13, 2005, 11:32:13 PM

Let me see...roughly speaking from memory (I haven't been keeping track...I could go back and count dollars and cents but then I'd run the risk of the wife finding out hehehe). All costs are in Canadian dollars.

bike: $7500 cash.
T3, 60 series Turbo: $200
50mm Wastegate: $140 (Thanks eBay)
Fuel and ignition parts: $450
Engine components from Schnitz: $600
VEMS fuel injection stuff $600
Raw metal for exhaust and intake: $150 (and counting)
MIG wire: $20
Headlights: $30 (Surplus Hella projectors)
'98 R1 seat: 99 cents (eBay baby!)
Paintball CO2 bottle: $40 (filled)
Air cylinder: $30
Swing Arm extensions: $100 (another eBay gem)
Air Filter: $30
Chopped oil pan $80
Oil and fuel line fittings: $100
Intercooler: $60 (you guessed it. eBay)
s2000 injectors: $220
Iridium spark plugs: Free!
Aluminum frame sliders: $30 (yeah. eBay again...seeing a trend yet?)
Centech wiring harness: $225

Total including bike: 10,406 (a new Hayabusa here is $15,000)
In US dollars: 6205 for the bike + 2404 parts = $8609 USD

Not bad for an intercooled turbo Hayabusa with (I hope) 300HP.

I still need a few things (chain, joints for uppipe & incooler, minor electrical stuff, Buell foot pegs, etc) but no one thing that's really expensive. Plus I'm sure I've left a few things out. And I'm not counting tools I made/bought for the project...I'd have bought them sooner or later, regardless.

And if you want to get really technical, subtract the parts I sold to make up for the parts purchased. I stripped everything off that wasn't required to make it run...streetfighter style. I know. That doesn't really count... unless you're trying to measure how much of a cheap bastard I am. :wink:

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: Busafied™ on July 14, 2005, 05:07:33 PM

intercooler pics?

Looking Good!

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on July 14, 2005, 10:55:52 PM

Quote from: Busafied

intercooler pics?

Looking Good!

As soon as it's mounted. I'm still figuring out the brackets.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: bajabug on August 10, 2005, 07:40:37 PM

Quote from: dtechnologies

\
And if you want to get really technical, subtract the parts I sold to make up for the parts purchased. I stripped everything off that wasn't required to make it run...streetfighter style. I know. That doesn't really count... unless you're trying to measure how much of a cheap bastard I am. :wink:

HAHA, the same reason i made my turbo busa a street fighter too. i guess ya gotta have priorities, and we know ours, BOOST!!

PS. i shaved near 70 lbs off my bike in body work and associated parts.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 10, 2005, 10:02:27 PM

I'm getting a little crazy with weight. My subframe and seat together should only weigh a few pounds at most (the wife will have to walk or get her own bike :lol: ).

I've got a carbon fiber race seat and chain guard coming as we speak...I'd give my left nut for a Catalyst carbon fiber tank. :twisted:

In other news, my aluminum velocity stacks came today! Hopefully I can build the plenum this weekend...pictures to come!

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: bajabug on August 10, 2005, 11:09:33 PM

any new pics? i hear ya on the carbon tank...very sweet part, especially the smaller drag one... i think id make an aluminum one b4 i would buy a carbon one.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 10, 2005, 11:24:37 PM

I'll have some pictures posted by the end of the week.

I considered having a custom tank made and just covering it with a fiberglass pro-stock tank...a friend of mine is trying to convince me to put the gas in the frame like a Buell...that's going a little far.

And I doubt the IHRA tech boys would pass it.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 15, 2005, 07:12:07 AM

I was only able to build half the air box on the weekend due to the fact that some of the aluminum I bought was wrong. I went as far as I could without needing the right stuff. I'll finish tomorrow I think.

I have pictures but my mouse crapped out so you'll have to hang tight until I can get a new one.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 16, 2005, 12:46:53 AM

Well due to a mismeasurement in regards to tank clearance, I bought the wrong size aluminum tube and had to improvise...what else is new. Because of this, I didn't get the plenum built on Sunday like planned. I'm hoping to get it finished tomorrow but it's almost impossible to find bent aluminum tube around here. I wonder if straight tube can be mandrel bent like steel pipe.

Here's what I've got so far:
(http://members.shaw.ca/dtechnologies/pics/webbusastacks.jpg)
Here are the aluminum velocity stacks I bought off the webertron. They're almost a near perfect fit. They're being held to the throttle bodies together with 43 cents worth of Heavy Duty rad hose...too bad I had to buy a 3 foot length for $2.60, hah!

(http://members.shaw.ca/dtechnologies/pics/webbusaplenum2.jpg)
Here's where things got screwed up a bit. I wanted 3"x4" aluminum tube but the metal shops didn't have any. I bought 4"x4" thinking it would fit based on my measurements...I was wrong. I cut 1 inch down the length with a jig saw, cut 4 holes in that plate for the stacks, then flipped it 180 to make a 3x4 which I will then weld or braze back together. I had to cut the left hand side at a bit of an angle to get it to clear the tank but only a little. As it's shown in the picture (mocked using zip ties to test clearance) it's just touching the heat shield in 2 spots...and only gently, the tank closes fine under it's own weight.

Right now I'm wrestling with how to get the inlet bent down and forward to go through the hole in the frame to meet up with the intercooler on the outside.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: Scary-Jerry on August 16, 2005, 05:21:12 AM

Quote from: dtechnologies

Right now I'm wrestling with how to get the inlet bent down and forward to go through the hole in the frame to meet up with the intercooler on the outside.

More radiator hose? :roll:

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: Bonedust on August 16, 2005, 07:51:32 AM

correwct me if im wrong, but isnt a square cornered plenum a tad tough on air flow?

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 16, 2005, 06:07:02 PM

Quote from: Bonedust

correwct me if im wrong, but isnt a square cornered plenum a tad tough on air flow?

It's less than ideal...I'm making do with what I have to work with. It's my hope that the velocity stacks will compensate a bit by smoothing out the flow as air enters the throttle bodies.

But I've seen uglier airboxes on turbo applications...

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 18, 2005, 07:11:25 AM

Last night I was finally able to mount the oil return line. I can't believe how little space I left myself...it wasn't easy to get the length right when you're only talking about a few inches.

The 2 halves of the airbox are together. I just have to put the sides on. And I still have to figure out the best way to do the inlet. Ideally, I'd like to have the inlet come in smack dead in the center but that would mean the intake pipe would have to be even more convoluted... I'm going to phone around today and see if any of the muffler shops in town have experience mandrel bending aluminum tube without cracking it.

My carbon fiber parts showed up yesterday. I'm very impressed with how strong and at the same time how light carbon fiber is. The seat and chain guard I picked up off of eBay are made by Feather Carbon. I must confess, I got what I paid for. The fit and finish isn't that great and the chain guard twists away from the rear sprocket when you bolt it down. The seller works directly with the manufacturer so I'm seeing if something can be done. Even though I would only consider these parts OK, I will definately buy more carbon fiber. I'd like to do the fenders and eventually the tank.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 18, 2005, 07:11:46 AM

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 20, 2005, 05:17:16 PM

I managed to get the phone number of the owner of Feather Carbon...we'll see what happens...hopefully it'll all work out.

I'm still tossing and turning at night trying to figure out how to connect the airbox with the intercooler. Between a severe lack of proper parts and an even more severe lack of funds, I've come down to a couple possibilities:

1) Go with a 2 1/4 inch plated steel pipe custom bent by a muffler shop using a press bender. This I think is the cheapest solution...but it'll look like crap...it's not like that ever mattered to me though.

2) Buy stainless steel mandrel U bends from a muffler shop (either 2" or 2-1/4"), cut them up and use multiple joints made from rad hose to join them all together. This is more expensive but I don't have a quote on stainless mandrel U bends yet. Like everything else that's specialty around here, they're likely to be overpriced.

The lesser of 2 evils. Non mandrel bends or lots of hose joints. I'm thinking plan 1 won't be too bad. Non mandrel bends are more restrictive but at 2-1/4" I don't think I'll notice the difference.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 20, 2005, 05:22:10 PM

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on August 21, 2005, 09:29:10 PM

So I'm using JB Weld as a backup to my brazed airbox and as a method of sealing up any little holes I may have.

While I was spreading it around like cake frosting on all my joints, I thought of a way to get a pipe made to connect the airbox to the intercooler:

I'm going to make a version using small diameter copper tubing...as I have a good bender for this handy already. I'll then take this to various muffler shops and simply say "I need one of these...but with a 2-1/4 inch diameter please". Eventually somebody should stop laughing long enough to say it's no problem and make it up...if things go well I may be able to do this to make a pipe which connets the turbine outlet and the intercooler too.

I also partially mounted the carbon fiber seat today. I like it (I can't forget to get a dry weight before I oil and gas it up for the first time). However...it's as warped as the chain guard and the holes weren't drilled straight. Just more ammo for the people at Feather carbon. I made a bracket with screwed up holes anyhow just in case they screw me.

Forgot my camera again...pictures to come.

Title: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on September 04, 2005, 01:21:44 PM

Quickie update:

Airbox is together and mounted. Intercooler will be mounted soon. Subframe is almost together.

I haven't worked much on the bike in quite some time. I had a week of vacation last week so I wasn't around and the day I got back I got a promotion at work...the money will be nice but working 13 hours a day hasn't left much time for getting anything done in the garage.

At the rate I'm going this will become a winter project, boo!

Title: Re: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: grecco on October 09, 2005, 10:03:44 PM

Got any more pics?
I'm impressed that you are doing all this yourself.
Keep us posted.

Title: Re: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: dtechnologies on October 13, 2005, 01:50:23 PM

sorry I haven't posted much lately guys. Work has been keeping me out of the garage in the worst possible way. I've been spending what little time I have at hom working on the electronics which isn't nearly as interesting as the bike itself.

I've also been hitting myself over the head trying to figure out how to mount the intercooler. It's going to be ugly, unconventional, and just plain gross...but if I want maximum boost, I have to install it.

The problem is that it's thick and it's flat and it's come out of a car so I can't mount it infront of the radiator. Right now the best place seems to be on the side of the radiator just above the air cleaner. It would have to be angled forward so that the intake piping will mate up with it but that shouldn't reduce it's efficiency too much. Because I don't plan on putting the body work back on, I don't have to worry about plastic clearances...though if I layed the bike down on the LH side, it would be the first thing to dissapear.

Title: Re: Frankenbusa Saga. 1/2 an airbox is better than none!
Post by: Bad Southern Busa on October 15, 2005, 08:57:30 AM

wOw IM truly impressed first time Ive caught your progress in quite some time ...keep up the good work and keep enjoying it !
you will have a special girl on your hands when ya get thru .

OH AND LET ME SAY NOW I UNDERESTIMATED THIS GUY.........i was one of the first ones to tell you when you started asking questions that you should just run out and buy something .
:x :? my apologies :o

way to go !!

Title: Re: Frankenbusa Saga. Do I have the record for longest project yet?
Post by: dtechnologies on December 31, 2005, 09:42:28 PM

My new years resolution is to finish my god damned bike and finally race it.

That is all. Carry on. :D

Happy New Year!

Title: Re: Frankenbusa Saga. Do I have the record for longest project yet?
Post by: denise richards on January 09, 2006, 05:38:42 PM

will you ever finish this one?i mean,theres not that much more to do.. :?

Title: Re: Frankenbusa Saga. Do I have the record for longest project yet?
Post by: dtechnologies on January 12, 2006, 07:42:13 PM

I'm tryin'

Considering I work 60 hours a week and don't even own a garage I think I'm making pretty good progress :wink:

This weekend is shot to because it's the motorcycle show is in town and the swag I ordered from Schnitz and MPS isn't here yet.

I pay so much to ship to the frosty north I went all out (all out for me) and ordered way more than i planned for. This post is going to get even longer yet. Here's some of the things I have to find homes for:
- MPS Low rise breather cover
- MPS 2 coil Shifter kill box
- MPS CO2 valve and regulator

- 1 1/4" fork lowering kit
- Vortex keyless gas cap (to go with my keyless ignition)
- Air shifter bracket.

Title: Re: Frankenbusa Saga. MPS Racing gave me the Schnitz!
Post by: dtechnologies on January 13, 2006, 08:46:34 PM

No sooner had I told you all that I can't work on my bike because the parts didn't come, than the parts came!

I went to UPS to pick up my MPS order and lo and behold my Schnitz order was there as well. To put the exclamation point on how much I hate ordering parts from the US It cost me $16 to ship from Schnitz and there was no duty or taxes or anything...that's the good news.

Shipping, Brokerage, Tax and Duty on the MPS order came to about $100 dollars (and MPS only charged $14 to ship).

This is neither the fault of the great people at MPS Racing or Schnitz Racing. This is a random attack by Canada customs and UPS who decided to randomly inspect the MPS order. This is why I ordered more than I needed. Paying an extra 25% isn't cool with me.

I have to say MPSs new billet breather cover looks great. I can't wait to install it. In fact all of the gear appears to be top quality. The only beef is that the fork lowering kit appears to also be compatible with a ZX-12...but that's more my dislike of Kawasaki talking, than anything that will prevent the forks from working.

Speaking of which. Can anybody recommend a good fork oil weight to help keep a lowered busa from bottoming out without giving a rock hard ride?

Now that I have this stuff, I'm missing very few parts and certainly the ones I am short I can find locally. My drive to get it done is re-sparked and I only have 3 months to do it.

Title: Re: Frankenbusa Saga. MPS Racing gave me the Schnitz!
Post by: TravG on January 14, 2006, 01:54:15 PM

Good luck, been following this for a while, I'd really like to see the final pics when you get it all worked out.

Title: Re: Frankenbusa Saga. Intercooler finally arrived
Post by: dtechnologies on February 28, 2006, 06:08:28 PM

I finally got my intercooler from FedEx yesterday. I'm excited because this one piece so far is the most expensive single part I've purchased on this project...I hope it fits.

(http://static.flickr.com/45/105688904_a1d801381c.jpg)

The good news is that it's very compact. The bad news is that because it's so compact, I think I'm going to need to count on the water to air set up being a bit more efficient for me to get the power I'm looking for. I still need to find a radiator (or radiators) but I don't need those to finish installing the rest of the up pipe assembly.

Title: Re: Frankenbusa Saga. Intercooler finally arrived
Post by: Busafied™ on February 28, 2006, 06:34:56 PM

Glad to see your still Keeping the dream alive-

GL,
Ron

Title: Re: Frankenbusa Saga. Intercooler finally arrived
Post by: reaper0995 on March 03, 2006, 09:53:43 AM

if your looking for a radiator for it, why not just use another busa radiator and place it in front of the one you already have?

or, if what i remembered right, you said you were going with no fairing, coorect? you could get a flat radiator for the engine, and then use a normal intercooler...but then your w/a intercooler peice you just got would go to waste..

good luck! you're an inspiration to me to go turbo home-style, just can't convince my "not wanting to bit the dust" side of me...

Title: Re: Frankenbusa Saga. Intercooler finally arrived
Post by: dtechnologies on March 04, 2006, 01:05:08 PM

Quote from: Busafied™ on February 28, 2006, 06:34:56 PM

Glad to see your still Keeping the dream alive-

GL,
Ron

Thanks for the vote of confidence Ron.

I'm having a hard time finding time with my crazy work schedule. I'm planning some vacation in the next 3 weeks so expect some progress...seriously this time! :lol:

Title: Re: Frankenbusa Saga. Intercooler finally arrived
Post by: reaper0995 on April 04, 2006, 10:29:42 PM

well, been a month now...any progress on the beast?

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: dtechnologies on April 05, 2006, 09:02:35 AM

Yesterday was the first day of 6 days of vacation which I book for no other reason than to get this monster together...and maybe even running! I'm starting to get comparisons to the movie 'The Fastest Indian'. Most of my friends figure I won't get it done until I'm in my sixties and all my friends and family have left me :lol:

Here's how things started yesterday (though this is after I'd pulled the old bars off)
(http://static.flickr.com/34/123727364_66d9c89d52.jpg)
As reaper mentioned it's been a month (or more). That month has been spent planning and getting all the parts together I might need so that I can put a solid week in and get it done. Unfortunately I've added a lot of plans onto the heap so there's still a fair bit to do.

Much of yesterday was spent digging out all my parts and the bike and getting is ready to be worked on. I also wanted to focus on getting the new handlebars on as I still need to order brake and clutch hoses and can't measure properly until the bars are in (and the forks shortened...I'm doing that tonight).

True to my love of streetfigher bikes I put a set of ProTaper bars on. I obtained these from a friend at a local salvage shop. I also got the fat bar clamps which I modified to use in this application. All I did was make an aluminum adapter plate and bolted everything together. I think the end result works really well and they seem to be comfortable from what I can tell sitting on the bike with no seat. I mounted the master cylinders, my MPS kill switch, and my throttle (a switched throttle from MPS racing). The levers don't line up quite as good as I'd have liked them too but they're functional. Today I'll be measuring to order custom cables from MotionPro.
(http://static.flickr.com/36/123727984_9563683f5c.jpg)
(http://static.flickr.com/1/123728196_2e22b508c7.jpg)
I also installed the air shifter bracket I ordered from Schitz. I like the under peg design better though ground clearance might be an issue.
(http://static.flickr.com/35/123728512_aea66e1618.jpg)
I mounted the chain so that I could put the new sprocket cover back on and measure for the clutch hose. I'm going to be fabricating a clutch slave from scratch...still no clue on how I'm going to do that with the cave-man-esque tools I have to work with.

Today I'll be trying to mount the intercooler...a big gamble...it may end up being put back on eBay where it came from.

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: reaper0995 on April 05, 2006, 01:39:53 PM

where are you thinking about placing the water/air unit?? under the gas tank or on the side of the bike right above the turbo??

cool stuff! hey, did you sell you left faring yet? how much if you haven't? my bike was dropped by previous owner and i want to cuctom paint it someday :D

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: dtechnologies on April 05, 2006, 01:51:44 PM

I'm trying to squeeze the cooler between the frame and the rad above the air cleaner. I might have been able to fit it under the tank infront of the plenum but that's where the water pump is going to live. So far so good but it sure is tight and I might need to get a slightly longer frame slider for the left hand side or risk busting it up good should the bike ever go down hard. Because of the length, I've had to spin the intake on the turbo 180 degrees so that the outlet is pointing down and to the rear, There's lots of room to put a 180 pipe out and up between the air cleaner and the stator cover. I'll have some pictures after lunch...or at least by dinner time.

I'll have to double check for your Reaper on the plastic. I've been without a body on my bike for so long, I can't remember which side I've sold.

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: dtechnologies on April 05, 2006, 05:48:13 PM

No matter how hard I work I always get the feeling that I'm not getting as much done as I should be. I've been in the garage all day now with nothing more than a sandwich break and the going has been as slow as ever.

My cables are measured up. Surprisingly enough, the stock cables are almost long enough. I just need to order some custom cables from MotionPro with Hayabusa ends on the engine side and fittings for their own push/pull throttle on the other with an extra inch or two in the length department. To be sure I'm getting what I need, I'm sending them the oem cables and throttle assembly so that they can match the inner cable length.

I also put on my Vortex race fuel cap. It's sweet anodized black and looks awesome.
(http://static.flickr.com/38/123928272_4e4f97dbf6.jpg)
(http://static.flickr.com/1/123928274_4cf052ad64.jpg)

Most of the day so far has been taken up with trying to finish the intake and fitting the intercooler. The good news is the intercooler fits. The bad news is that getting the plumbing to make a path between one side of the intercooler to the turbo and the other side to the airbox is driving me mental. I've had to modify the outlet on the compressor housing and fabricate a tight 90 degree elbow. The pictures show mid-process before I cleaned up with some grinding and sanding.
(http://static.flickr.com/39/123928962_f0f1f533b0.jpg)
(http://static.flickr.com/36/123928964_944af225e3.jpg)

Hopefully I won't run out of bent tubing before the end of the day or I'll have to go buy more tomorrow.

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: nemsis on April 06, 2006, 01:48:16 AM

keep it up it's looking good

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: dtechnologies on April 06, 2006, 10:29:17 AM

Last night I finally got the intake air plumbing together. When it was done I stood back and laughed my ass off. To me, this is by far the most ghetto thing I've done. The bottom pipe is awefully low but it's not the lowest part...I measured and it seems to be fine. Snaking the rad hose is going to be tight. I'll likely have to replace it with a silicone hose that has a bit more flex to bend around the intercooler and the air cleaner.
(http://static.flickr.com/41/124232804_39dd8c2a27.jpg)
(http://static.flickr.com/48/124232807_53ecbbfc85.jpg)
The second picture makes it look much lower than it is because of the angle I had the camera at. When the front wheel is back on, I'll tip the bike to make sure the pegs hit before the pipe does...but it should be OK if I've measured properly. Next step is to clean up the pieces and clean up the header at the same time. They all need to be painted as they're made of steel.

I was planning on shortening the forks yesterday...until I realized I couldn't find the instructions the kit came with. As soon as I'm done typing this I'm going to call Schnitz and hopefully they can email me a copy. The forks are going to be an adventure for sure since I have NO fork tools. I could likely wing it using just the service manual but I don't know if the instructions call for the springs to be cut or not.

I decided to go with 10wt oil. We'll see how that works out. Since none of my posts had replies to them, I'll be sure to let you all know how 10 works out...possibly prevent somebody else from buying the wrong weight.

As soon as they're shortened and back on I can measure for brake lines. While I'm at the dealership ordering those, I'll be having my front tire replaced with a 60 series to get that last little bit of lowering/rad clearance. Hopefully this will happen tomorrow.

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: reaper0995 on April 06, 2006, 01:47:28 PM

if you are too short on the piping and need more clearance for your inake pipes from the ground, couldn't you just shorten them?? it looks like you might be able to get 1/2 to an inch off them if oyu really needed....but it might just be the angles...keep it up bro! :D

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: dtechnologies on April 06, 2006, 02:18:42 PM

Thanks Reaper,

You're right, I do have some play to chop a bit if needed. Also, because there's no clamps on anything in that picture, the weight of the cooler is making that whole chunk sag a bit...without the bungie it would fall off.

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: dtechnologies on April 06, 2006, 02:23:48 PM

Mo mod, mo problems.

So after spending most of the morning on the phone and getting the fork kit instructions emailed to me from the lovely ladies at Schnitz, I was ready to start on the forks. I cleaned the bench extra careful like and took the forks out.
(http://static.flickr.com/1/124322029_1865b635f3.jpg)(http://static.flickr.com/45/124322030_df940cb282.jpg)

Once on the bench I noticed something that made my stomach turn.
(http://static.flickr.com/55/124322031_d7c45fc675.jpg)

A nasty ass scratch. The picture is a bit blurry but rest assured the scratch is wide and all the way through the chrome.

I'm not sure what to do and I have no idea how or when it happened...the bike had been crashed twice before I got it but the forks have never leaked. I don't want to rebuild the forks if they're just going to leak when I start riding. With the forks shortened 1-1/4", the chances of that gouge F-ing up the seals is hightened greatly.

Any suggestions?

Title: Re: Frankenbusa Saga. The Eleventh Hour
Post by: dtechnologies on April 07, 2006, 03:42:52 AM

Time is something I don't have much of so tomorrow I'm going to rebuild the forks as-is...I'm sure it won't be too bad. I can't afford to replace fork tubes anyhow.

While I didn't get much done today, I did manage to get a few things done...

I mounted up the carbon fiber chain guard I picked up on eBay. I strongly recommend a person steer clear of eBay when it comes to carbon fiber. This chain guard was warped slightly. I resolved this by using a zip tie to secure the guard to the brace of the swing arm. The added benefit of this is that it makes the guard more rigid.

I've also started mocking up aluminum to fabricate my solo subframe with carbon fiber race seat. It's going to be short, stubby, ugly, and should be super light and have just enough room inside for the engine computer and a few other electronics goodies. The carbon fiber seat (from the same guy as the chain guard) is also warped but it won't show once it's bolted down and my fat ass is on it.

(http://static.flickr.com/54/124594973_5a3e4f4929.jpg)

Three days to go before I have to go back to work...

Title: Re: Frankenbusa Saga. The Eleventh Hour. Forks be shortened!
Post by: dtechnologies on April 08, 2006, 08:12:59 PM

The last two days have not been nearly as productive as I'd planned. Despite having the week off for vacation, I'm still not getting much done. The good news is that so far today I've made some good progress

First, I picked up a BT020 120/60-17 for dirt cheap at a local dealership. Seems people don't like this tire but I love it. I had great luck running it on my FZ1. It was on sale so including mounting and balancing I only paid $160 CDN. You can see it's size compared to the old 70 series tire...should give me about 1/2" lowering and another 1/2" clearance to the rad.
(http://static.flickr.com/39/125404573_5c3fdec6be.jpg)

Being very eager to get to the forks, I dove in. Finally I have all the tools, oil, instructions, and everything else I need. I decided to do them one at a time so I could compare them assembled.

I started by taking one apart:
(http://static.flickr.com/40/125404575_6969e0f46c.jpg)
Then set to work taking the insides apart. Without proper Suzuki tools, this is quite the task. The instructions from Schnitz were OK but could have been better. I admit I got pretty nervous when I had to use a pipe wrench to seperate a piece from the inner cartridge. Because everything is being done backwards due to a lack of tools, I had to make my own spring compression tool:
(http://static.flickr.com/54/125404580_b30deacebc.jpg)
The reason the cartridge has to be taken appart is so that a small spacer can be put in to compliment the shortened main spacer...pretty smart:
(http://static.flickr.com/1/125406530_8dd88063b3.jpg)
The Completed cartridge:
(http://static.flickr.com/44/125406531_febe353d2f.jpg)
The time had finally come, I could stand them next to each other and compare. I was pretty happy at this point.
(http://static.flickr.com/1/125406532_28e4d46c44.jpg)
Even though I have to pull the turbo and header off, I had to see what the bike was going to sit and look like back together.
(http://static.flickr.com/50/125406534_7f1c05bc34.jpg)
Here's a shot showing ground clearance. Quite a bit by my estimation thanks to that lowered oil pan (no peanut gallery commentary required).
(http://static.flickr.com/45/125407246_9b22be598e.jpg)

Title: Re: Frankenbusa Saga. The Eleventh Hour. Forks be shortened!
Post by: dtechnologies on April 09, 2006, 01:29:10 AM

Well I managed to get a bit of work done before heading in for the night.

First I wanted to see how far the bike would lean with the newly lowered front end...and it's not good news. With the forks shortened and the 60 series tire on the front, the bike can't lean very far.
(http://static.flickr.com/41/125527490_08c38d29ee.jpg)
I guess I'll have try and get a bit more clearance when I do the final mounting of the up-pipe pieces...or make sure all hard turns are to the right :lol:

I also mounted the front brake calipers and was pleasantly surprised to see that the shortened forks have provided a perfect amount of slack to make up the difference. I won't be ordering new brake hoses now...not unless there is a clearance issue with the radiator and the cross over hose.
(http://static.flickr.com/48/125527493_408a91f268.jpg)

I spent a lot of time today trying to decide on how to build the subframe. I mocked up different things with aluminum and so far haven't found anything I like. One of my plans was to put the ECU and other electronics into the subframe but the smaller I make it, the more I like it. Tomorrow I'm going to try switching to steel and making it very small. This will force me to get creative to locate the ECU and such but I'm much better at being creative with wiring than with raw steel.
(http://static.flickr.com/51/125527492_64f44707a9.jpg)

Title: Re: Frankenbusa Saga. The Eleventh Hour. Finally some progress!
Post by: dtechnologies on April 09, 2006, 02:10:31 PM

It's definitely too little too late to get this project done before I have to go back to work tomorrow but I'm a hell of a lot closer.

I played with some subframe stuff last night and ended up with some aluminum framing but I guess I needed a good nights rest to get it done. I brazed the pieces together this morning and what I ended up with not only holds my weight but took several blows from a 2 lb. deadblow...that's good enough for me.
(http://static.flickr.com/49/125830727_c2ffbe28ed.jpg)(http://static.flickr.com/37/125830726_a8c480b9f1.jpg)

At this point mounting the rear brake master cylinder was a snap:
(http://static.flickr.com/51/125832104_ba2dbc48ff.jpg)

With all that angle aluminum I was inspired to mount the headlights...something I'd been struggling with:
(http://static.flickr.com/49/125830730_f3744a67a3.jpg)(http://static.flickr.com/53/125830729_14f1ba9cb8.jpg)

On a whim I decided to install the 24-1 stator wheel I picked up. I still have no rock solid way to measure how many degrees before TDC the gap passes the sensor...I guess I'll end up spending a few hours with a degree wheel one of these nights.
(http://static.flickr.com/49/125830732_262416f3ef.jpg)

One of the things I've been thinking about a lot but have been putting off is mounting the battery in the swing arm. I mocked up a few things and this is what I came up with:
(http://static.flickr.com/52/125832108_86da1b23ea.jpg)(http://static.flickr.com/53/125832106_d4131722d1.jpg)
The shelf is 6061 Aluminum and will be attached to the swing arm using 1/4" threaded rivet inserts. I still need to trim it so that it slots around the chain guide and the rear brake support rod ear. The black bottle is a 20oz. paint ball bottle with an MPS valve and regulator and the aluminum bottle is a camping fuel bottle which will be used for tank, rad, and crank case overflow to meet racing requirements. I might switch to two smaller bottles and dedicate one to coolant so I can recirculate the coolant, eliminating the requirement for yet another container/bottle.

Title: Re: Frankenbusa Saga. The Eleventh Hour. Finally some progress!
Post by: dtechnologies on April 09, 2006, 04:00:24 PM

If you haven't noticed by now I'm uploading all my pictures to Flickr. It's a fantastic service.

If you go to http://flickr.com/photos/tags/frankenbusa/ you'll see all the photo's tagged 'Frankenbusa' which should obviously be all the project photo's of my bike both new and old...if you care.

Title: Re: Frankenbusa Saga. The Eleventh Hour. Finally some progress!
Post by: nemsis on April 09, 2006, 04:19:44 PM

nice

what are you using for headlights?

for that chain guard is their anyway you can screw it into the swingarm bracing from the back side and get rid of that wire tie

Title: Re: Frankenbusa Saga. The Eleventh Hour. Finally some progress!
Post by: dtechnologies on April 09, 2006, 05:01:03 PM

Quote from: nemsis on April 09, 2006, 04:19:44 PM

nice

what are you using for headlights?

for that chain guard is their anyway you can screw it into the swingarm bracing from the back side and get rid of that wire tie

The lights are Hella Optilux foglamps. I'm going to put some Eutrolite Xenon bulbs in to give them that HID feel. If I remember I'll do them one at a time and try to take a picture of the difference in their look.

I do intend to do away with the zip tie but it's not a high priority. Because of the curve in the brace, it doesn't sit flush on the inside. What I'll likely do is drill a hole in the brace and thread it ( or put in a blind threaded insert) and an angle cut spacer to bridge the gap.

Title: Re: Frankenbusa Saga. The Eleventh Hour. Finally some progress!
Post by: dtechnologies on April 09, 2006, 09:07:55 PM

Somebody asked me today what I had left to do on my bike. After listing just some of the things I need to do yet, their comment went something like, "Holy crap. It's like you're building the thing from scratch!" I hadn't realized it but in a lot of ways that's what I've been doing. I don't feel so bad for taking so long now.

Title: Re: Frankenbusa Saga. The Eleventh Hour. Finally some progress!
Post by: dtechnologies on April 10, 2006, 08:00:23 PM

Finally got to a computer to fill in yesterdays pictures.

Here a couple of shots of the battery shelf once I finished installing it.
(http://static.flickr.com/53/126665331_af9467e201.jpg)(http://static.flickr.com/54/126665380_68d1ad12ce.jpg)(http://static.flickr.com/48/126665404_ce1862c29b.jpg)

Getting under the bike was a bitch. If it weren't for the hoist, I don't think I'd have been able to do it
(http://static.flickr.com/1/126665301_dbf46feed3.jpg)

I went back to work today and was asked 'Is it done yet?', 'Did you get it running?', etc, no less than 5 times...I've definately been doing this too long.

I shipped my throttle cables to Motion Pro today. That bad news is 5 days there, 8 business days to make them, and 5 days back again. The good news is that the quote was only $30 a cable plus return shipping.

Today I'm taking the day off. There's wrestling to watch and sleep to catch up on.

Title: Re: Frankenbusa Saga. Stomach Flu Sucks
Post by: dtechnologies on April 12, 2006, 07:53:29 AM

I have good news and bad news and unfortunately both are preventing progress.

I've had a touch of stomach flu for the last couple of days and been spending some quality time in the bathroom. Since I don't work on my bike at home and it's highly contageous, I've decided to quarantine myself for a couple of days. :(

The good news is that I've just learned that starting this weekend I'll be getting ready to become an instructor at one of Alberta's largest motorcycle rider training schools. I'm super excited. I might buy another bike (a beater) this week just so I have something to ride while I'm finishing the Frankenbusa as it's going to take more time once I start teaching.

Title: Re: Frankenbusa Saga. Stomach Flu Sucks!
Post by: dtechnologies on April 12, 2006, 04:40:57 PM

My APE studs and nuts came today...at least I picked the right day to be sick.

Since I ordered them I can't decide if I want to go to all the work to put them in now. I might just retorque the head and clamp them down tighter than the manual recommends.

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: dtechnologies on April 18, 2006, 11:26:47 PM

My hours have been changed at work so that I'm now working the night shift and have Mondays and Tuesdays off. Because I drive 40 minutes to work on my bike, this means I need to move my bike a LOT closer if I'm going to get this damn thing done this year.

So far I have no solutions beyond quitting my job...which isn't an option.

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: reaper0995 on April 18, 2006, 11:36:13 PM

Quote from: dtechnologies on April 18, 2006, 11:26:47 PM

My hours have been changed at work so that I'm now working the night shift and have Mondays and Tuesdays off. Because I drive 40 minutes to work on my bike, this means I need to move my bike a LOT closer if I'm going to get this damn thing done this year.

So far I have no solutions beyond quitting my job...which isn't an option.

living room buildup! :twisted:

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: dtechnologies on April 19, 2006, 08:53:41 AM

Quote from: reaper0995 on April 18, 2006, 11:36:13 PM

Quote from: dtechnologies on April 18, 2006, 11:26:47 PM
My hours have been changed at work so that I'm now working the night shift and have Mondays and Tuesdays off. Because I drive 40 minutes to work on my bike, this means I need to move my bike a LOT closer if I'm going to get this damn thing done this year.

So far I have no solutions beyond quitting my job...which isn't an option.

living room buildup! :twisted:

I've considered that...it may happen yet.

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: reaper0995 on April 19, 2006, 11:03:09 AM

how much do you have left on it? it looks like a little on the turbo setup, radiator for intercooler, tail section, handlebars, swingarm stuff...tuning....anything else other than the normal small put together peices??

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: dtechnologies on April 20, 2006, 12:26:33 PM

Here's my current 'to do' list:

- Mount the seat to the subframe
- Find the holes in the header and dump and plug them.
- Paint all the exhaust and up-pipe sections with VHT 1500 degree paint
- Re install all those pieces plus the wastegate and BOV.
- Install the MPS low rise crank breather cover
- Re-plump the fuel system to better utilize the increased under tank space
- Scratch build a clutch slave support
- Buy and install a steel braid hose for clutch
- Find rad(s) and plump the intercooler
- Mount the water pump, the ECU, the MPS electronics air shifter valve, the reg/rect, and battery
- Install air shift cylinder and air hoses
- Install throttle cables (when they get back from Motion Pro)
- Mount signal and brake lights
- Mount some switches somewhere for lights
- Install ignition switch somewhere
- Mount my Veypor VR2 speedo and harness
- Handwire EVERYTHING
- Retorque head to ~45lbs.
- Get to tuning!
...
- Anything else I forgot...

It's still a fair bit of work but each step individually shouldn't take long. It's getting out there to do it. I'll have this coming up Monday-Tuesday and maybe the next before I start teaching again. If I can narrow the work down to electrical and some basic assembly by then(aka: get the dirty stuff done while I still have a garage), I'm pretty sure a living room finish is in the picture.

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: reaper0995 on April 20, 2006, 12:41:25 PM

WOW! :bah:...thats a lot on the plate still.

(http://www.scottjbaugh.com/Design_Portfolio/Living%20Room.jpg)

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: dtechnologies on April 20, 2006, 10:28:41 PM

Compared to what I've gone through so far this is nothing. The road has been long and twisty but there's light at the end of that tunnel.

During this journey I've learned a lot. Most of which is thanks to the kind folks on this forum...without their support, I wouldn't have been able to take this to the level that I have.

When I started, this project was a 'I should put a dry shot of nitrous on' and becamse 'put a turbo on my 'busa' project and now it's a complete transformation into a creature that is part turbo hayabusa, part street fighter, part junk yard leavin's, but all me.

I'm sure most will look at my bike when it's done and call it the biggest piece of shit they've ever seen but I've never been satisfied to have something that is even remotely close to something somebody else has.

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: reaper0995 on April 20, 2006, 10:40:51 PM

well, then what about that gas tank...it looks like mine :lol: :lol: :lol:

i think its pretty cool. lots of work makes for some cool stuff. i really like the way the swingarm and tail section so far looks. it really compliments well and the distance between looks cool 'cause you don't ever see it like that.
(http://static.flickr.com/49/125830727_c2ffbe28ed.jpg)

Title: Re: Frankenbusa Saga. Progress slows once again.
Post by: gsxturbo on April 22, 2006, 02:02:13 AM

Quote from: dtechnologies on April 20, 2006, 10:28:41 PM

Compared to what I've gone through so far this is nothing. The road has been long and twisty but there's light at the end of that tunnel.

During this journey I've learned a lot. Most of which is thanks to the kind folks on this forum...without their support, I wouldn't have been able to take this to the level that I have.

When I started, this project was a 'I should put a dry shot of nitrous on' and becamse 'put a turbo on my 'busa' project and now it's a complete transformation into a creature that is part turbo hayabusa, part street fighter, part junk yard leavin's, but all me.

I'm sure most will look at my bike when it's done and call it the biggest piece of shit they've ever seen but I've never been satisfied to have something that is even remotely close to something somebody else has.

man its all about what makes you happy lifes to short to worry about what everybody else thinks i think you you have done a fine job with what you have had to work with considering how hard it is getting parts and making everything yourself keep up the good work

Title: Re: Frankenbusa Saga. Damn those Germans!
Post by: dtechnologies on April 24, 2006, 12:48:32 PM

Well my cables are in limbo. It's been 2 weeks and they still haven't arrived at Motion-Pro...5 days my ass. I put on the package that the cables are going to 'be serviced' so that no duty would be charged...no doubt they're sitting on them trying to decide if I'm pulling a fast one or not...fucking customs.

Additionally, I found a part that I absolutely must have for my bike! Unfortunately it's from Germany and not cheap. By the time it gets here, it would cost me over $300 CDN but I can't find another piece like it for less. Plus it has a small area at the front where lights or small gauges can be mounted. Seems like too much money for this (unpainted no less):

(http://www.big-bike-online.de/shop/contents/media/tank2klein.jpg)

It pains me to no end that I don't have the ability to make something decent to bridge the gap between the tank and the frame. It's just too irregular an area and I don't have the tools or the skills.

Does anybody have any suggestions?

Title: Re: Frankenbusa Saga. The shit has hit the fan
Post by: dtechnologies on April 25, 2006, 01:11:46 PM

Thanks to my wonderful employer and a few other tricks that life has thrown into the mix, this is very very likely to be the last day I'll have a garage to work on this project in. I'm trying to get everything done today that I absolutely need a garage for...I'm realizing that it's too little too late. Tomorrow I have a meeting with my boss and his bosses...I might have more time (and a lot less money) depending on how that goes...

I modified the last elbow between the up pipe and plenum to accept my BOV this morning. It's a cheapy but I took it apart and the construction seems solid...and it was free. I modified it a bit so that it would fit better. I'm getting fairly good at welding with my cheap borrowed MIG. I'm sure there are still a few holes that I'll need to plug after it's painted...epoxy is my friend.
(http://static.flickr.com/56/134969312_4b90f28abd.jpg)

Speaking of epoxy, I've also mounted a bung for the intake air temperature sensor. I had to mount it off center between carb 3 and 4. I wanted to put it right in the middle but there just isn't room. Plus I don't think I've ever seen a sensor located anywhere but on the side. I had to use a flanged steel nut with recut threads. I'll run a tap through again once the epoxy is set to be sure and then hit it with a quick shot of paint just to be sure it doesn't rust. I could have bought a stainless nut I'm sure but at this point I just don't have the time to fuck around.
(http://static.flickr.com/53/134969314_867a28b90d.jpg)(http://static.flickr.com/55/134969315_6dfb082c19.jpg)(http://static.flickr.com/51/134970363_b06fc70338.jpg)

After lunch I'm going to try to clamp the throttle bodies to the head using standard hose clamps as somebody mentioned earlier that it can be done and dis-assemble the headers. I need to be sure the dump and gate all fit properly (some of the bolts are at odd angles) as tonight I'm going to see if I can't acid bath all my steel parts and paint them with VHT 1500 degree paint. I may use regular engine enamel for the up pipe sections but only if I don't have enough VHT to go around. Any holes at that point will be plugged with high temperature exhaust cement.

Title: Re: Frankenbusa Saga. The shit has hit the fan
Post by: dtechnologies on April 25, 2006, 03:07:41 PM

Well my after lunch plans have changed already.

It would seem that my work related stress is taking it's toll on my ability to concentrate on just about anything. I was emailed an article about abuse in the workplace and the similarities to what's been happening to me at work lately are sobering. I have to leave. I'm going for a ride to clear my head.

I also had a great idea on the way to pick up my bike. Something that I've been struggling with is how to determine how many degrees before top dead center the missing tooth on the stator wheel passes the sensor. I think I've figured out a way. I remembered that I have an extra stator cover that I got from a laid down 'busa. I'm going to cut a big ass hole in the side of it right where the VR sensor is and one where the crank shaft is. I'll spin the motor to TDC and then turn the motor until the missing tooth is at the sensor. I'll use a degree wheel on the crank to measure. Home made tools rule.

Title: Re: Frankenbusa Saga. The shit has hit the fan
Post by: dtechnologies on April 25, 2006, 09:46:36 PM

I did some welding on my headers this afternoon to patch visibles holes...but I ended up burning more holes than I patched...either I'm not as practiced as I thought or I got a little crazy when I was grinding.

I managed to put together my stator cover idea and I think it will work quite well. Because everything is one piece I can't mount the VR sensor without the stator but with the mounting holes for the sensor visible it's an easy matter to just measure for the center line between them. I didn't get a chance to actually measure anything today. I'm sort of scared to turn the crank. The engine hasn't run for so long and has had no oil for almost as long.
(http://static.flickr.com/49/135146441_197d4b3c31.jpg)(http://static.flickr.com/55/135146442_7e73d77aca.jpg)

I'm definately not going to meet the deadline I set for myself of May 1st. :(

Title: Re: Frankenbusa Saga. The shit has hit the fan
Post by: reaper0995 on April 25, 2006, 11:57:14 PM

afriad of no oil? i have an idea....i saw this in a hot rod magazine. it was a product that essentially was an air canister that would turn to the on position when the key was in accessory mode. then you leave it there for a few seconds, then start your motor. was supposed to remove the wear/tear on the engine startup to 'protect your investment' or something. now my idea is to take off the oil pressure sensor that most people T off for the turbo feed line, then make a tiny adaptor and connect one of those air blowers from a compressor. then just add a little bit of pressure, see what it does (like nothing is going on bad...), then maybe add a little more. might push a little oil through your system, or something like this.

now, it might be a good idea to wait and see what other people have to say about this one before doing it, for i have never done this. just sounds like it could work, or at least not be any more harmful than it would be to turn a non oiled crank. :P :| :( <---hopefully not the :(

Title: Re: Frankenbusa Saga. The shit has hit the fan
Post by: dtechnologies on April 26, 2006, 12:36:06 AM

I've heard of those. It's basically a canister that's half full of oil and half full of air at about 80-90 PSI. It has a valve on one side and a gauge on the other. Just before you start the motor you open the valve and the air pressure forces the oil into the engine. Once the engine comes to temp, the oil pressure refills the cannister, compressing the air in the can at the same time. Once the gauge shows 80-90, you close the valve and it's ready for next time.

I think that would work on a bike but the volume of oil would be lesser and the pressure would be greater. I have a 10oz. nitrous bottle sitting around not doing anything...I wonder if that would work.

Just what I need...more projects :D

Title: Re: Frankenbusa Saga. The shit has hit the fan
Post by: reaper0995 on April 26, 2006, 01:04:45 AM

Quote from: dtechnologies on April 26, 2006, 12:36:06 AM

Just what I need...more projects :D

oops :D, but uhh, you arent gonna use nitrous in that bottle to pressurize...right? might get a little molasses for oil :wink:

Title: Re: Frankenbusa Saga. The shit has hit the fan
Post by: dtechnologies on April 26, 2006, 01:38:55 AM

It's just a throwback from when I wanted to keep things simple and do a dry shot of nitrous.

Maybe once it's up and running I'll experiment. God knows I don't have the time now. I could use the fitting for the cam chain tensioner. I'm defying all suggestions and putting on a manual tensioner because I don't have the time or inclination to modify the OEM tensioner to match my spacer plate.

Best I can tell, this would force oil into the main gallery. A good place I figure however it might push oil into the filter in the opposite direction than intended...I have no idea what that might result in.

Addendum: I did some internet searching and found http://autoenginelube.com/pages/903473/index.htm. It's pretty much exactly how I'd think to build it only it's using an electric solonoid valve and I'd use the smaller 10oz. tank. You'd almost have to know how much oil the engine holds (in the galleries and bearings, etc) and how much you can semi-safely overfill the engine with oil just in case the device fails and that extra oil ends up in the engine all the time...withhout the oil cooler, it can't be much.

Title: Re: Frankenbusa Saga. Motion Pro to the rescue.
Post by: dtechnologies on April 26, 2006, 11:15:04 AM

I just got a call from Motion Pro. They finally got my cables. Unfortunately their time quote has been extended and the cables won't be completed and shipped until aprox. May12th. That's not as big a deal now that my May 1st goal is completely unattainable anyhow.

$30 each. Amazingly cheap.

Title: Re: (The Never Ending) Frankenbusa Saga.
Post by: dtechnologies on April 26, 2006, 11:43:21 AM

I was just on the Moroso web site and I learned something interesting. These pre-oiler devices are also known as oil accumulators. They're used in sprint racing to keep extra oil on presurized tap in case the oil pickup runs dry due to hard cornering, etc.

I can't help but wonder if the same thing would help a bike from running dry if one 12 o'clocks a wheelie off the line at the track?

Very interesting...

Title: Re: (The Never Ending) Frankenbusa Saga.
Post by: reaper0995 on May 12, 2006, 12:22:46 AM

hey dt, so whats the scoop? did you have to move the bike after all? did that half gsxr rad. thing work out after all in dimensions to be used as a w/a intercooler? cool man, good luck with whatever is coming to ya!

Title: Re: (The Never Ending) Frankenbusa Saga.
Post by: dtechnologies on May 12, 2006, 01:41:42 AM

Sorry for a lack of updates but working a 3pm to 9pm shift leaves me without much time to work. Next week it gets worse with a 3pm to midnight shift...but I'll have weekends off at least so work can continue.

My cables came yesterday from Motion Pro. Worth every penny. They're incredibly high quality for only costing $30 each...easily as good or better than the originals. As usual, UPS charged me $4 in tax and $35 in brokerage fees making $60 in cables over $100. As soon as I can get out there I'll install them. I hope my guess on length was right.

As far as the radiator I did some quick measuring and ended up getting a GSXR600 rad off of ebay for just over $100 after shipping. A bit more than I planned to pay but it's in good shape and comes with a fan that I might be able to use to set up a dual fan rig.

For right now she's staying put. I'm not sure for how much longer though. I had set myself a deadline of May 1st to get it done but that was before life started kicking me in the nuts every other day.

I'm on the cusp of quitting my job and becoming an apprentice welder...so my free time situation might change soon.

Title: Rad has arrived.
Post by: dtechnologies on May 12, 2006, 11:19:37 AM

I picked up the radiator this morning. It's actually smaller out of the bike than I thought it was in one...nice and thin. I'll have to wait until it's up into the bike but if I didn't know better (do I ever?) I'd say it would fit right up there whole and take up less space than an air2air intercooler would in it's place.

It's going to need some modification regardless and I haven't decided if I should try to solder it myself or if I should take it to a professional this time....whoa! who said that!

Title: Re: (The Never Ending) Frankenbusa Saga.
Post by: Slyder on May 12, 2006, 05:43:43 PM

Dude are you married?
I wish I had all the time you have.
Actually I think I'm just jealous.
Nice ride. I can't wait to see it finished.
:D

Title: Re: (The Never Ending) Frankenbusa Saga.
Post by: dtechnologies on May 28, 2006, 01:17:28 AM

The throttle cables are installed...I'm sure some of you were hoping for more progress than this but right now the bikes under a sheet as a garage sale goes on around it. Hopefully things will pick up soon. There's a chance that there will be a promotion waiting for me when I go back to work on Monday....that would accelerate things a bit...not to mention the extra $$$ :D

Here's some pictures of the cables. 2" longer seemed to be a good guess. I didn't have time to check 100% to make sure they don't pinch, pull, or bind but I don't think I could have guessed closer. The headlight bracket might need to be cut as you'll see in the pictures but other than that I think they're fantastic:

(http://static.flickr.com/45/154608969_0c37f0b8b4.jpg)
(http://static.flickr.com/76/154608892_f2668bdf9f.jpg)
(http://static.flickr.com/78/154608820_5bb62e93de.jpg)
(http://static.flickr.com/66/154608758_22dcc0b819.jpg)

I really can't say enough great things about these Motion Pro cables. Their service was amazing, there was only an 8 day turn around time on making them from scratch (I can't hold long shipping times against them) and they only cost me $30 each plus shipping...truly one of the greatest buys for something new throughout this entire project. I might call on their services again if needed as I'll need to connect a solenoid to the 'fast idle' linkage on the throttle bodies. My custom ECU will be managing fast idle for me based on engine temperature.

Title: Re: (The Never Ending) Frankenbusa Saga. New job = New hope
Post by: dtechnologies on June 06, 2006, 05:05:33 PM

There haven't been any real serious updates in a while. I want to let anybody following this thread know that the rough seas seem to be over for me as I've just been promoted at work. With a bit more cash to go around and a 4 day work week I should have whast I need to finish things up while there still summer left. If I'm lucky I'll be able to enter in the latter of the two CMDRA drag events here in Edmonton...though that might be thinking TOO far ahead.

Right now my bike is under a sheet while a garage sale happens around it. But next weekend work will commence again and as I have 99% of the parts I need. I believe that things should go rather smoothly....knock wood.

Title: Re: (The Never Ending) Frankenbusa Saga. New job = New hope
Post by: reaper0995 on August 05, 2006, 07:06:00 PM

dtech, where you been? we miss ya project :D

hope things are going good

Title: Re: (The Never Ending) Frankenbusa Saga. New job = New hope
Post by: dtechnologies on August 09, 2006, 09:53:25 PM

Sorry folks but planning a wedding is more time consuming than I ever imagined. Also, my dad (who's garage I'm using) retired 2 weeks ago after being a mechanic for 28 years. The garage now has about 5 tool boxes and A LOT of his accumulated 'stuff'...not to mention my ever growing project 'stuff' (stuff=junk). I'm going to have to help him clean it up if I'm going to have room to get work done. Even though I'm getting married in 60 days, things are starting to get finalized and I should have some good solid evenings and weekends soon to hammer out a fudge just in time for winter.

In fact speaking of fudging it...at this point I'm ready to cut a few corners. All I really need to do to get it running is finish the intake air plumbing, headers, the intercooler plumbing and wire up the ECU. Then I can get the engine running and start tweaking the software. Lights, fenders, and all that street legal jazz can come later (possibly winter). I think I'm going to just clean and paint the intake and header parts and worry about leaks later...exhaust cement and jb weld will be my friends. And the street legal parts of the harness likely won't be done until very last. I'm trying to track down some carbon fiber on the cheap as in the end I want the front and rear fenders to be carbon. I'd like to buy a Catalyst carbon tank too if it's ever in the budget.

One other tiny update is that I purchased a Veypor VR2 speedo/computer(www.veypor.com (http://www.veypor.com)). Insted of letting it collect dust, I put it on my XJ750. It's the most awesome piece of hardware. Plus, it can hold profiles for up to 4 bikes so I can use it on both bikes and all I'll have to do is buy another harness for $40.

I really want to try out the wireless helmet mounted HUD...it's right up my geeky alley. Unfortunately money is tight these days (weddings are also more expensive than I ever imagined). If anybody is interested in ordering one, hook me up with the referral discount and use my referral number of 3121. Once I find a way to weigh the XJ, I'll try out the 0-60, 1/4 mile, roll on, and dyno functions and post a review in another section...to put it simply just based on using it when riding to work and back...it's awesome!

Title: Re: (The Never Ending) Frankenbusa Saga. New job = New hope
Post by: Busafied™ on August 15, 2006, 05:29:37 PM

Good to see your still going forward, no matter the pace-
I know when I built mine last yr, it was the culmination of 4 yrs research.

Patience is not one of my strong points.

I have been really intrested in the Veypor Sys, since it's inception- still not in the budget though.
Especially since I am rebuilding mine ground up, and in the middle of moving :x :?

GL on your project Dave-
Ron

Title: Re: (The Never Ending) Frankenbusa Saga. New job = New hope
Post by: reaper0995 on September 29, 2006, 10:34:35 PM

how are things man? been a while since the org been down for a little bit. missed seeing this one!!

Title: Re: (The Never Ending) Frankenbusa Saga. New job = New hope
Post by: grecco on October 16, 2006, 08:51:59 AM

bump.
dtech,
you still out there?
hows it going?

Title: Re: (The Never Ending) Frankenbusa Saga. New job = New hope
Post by: dtechnologies on October 30, 2006, 04:38:31 AM

Hi folks.

I've been out of the garage for quite a while due to my wedding but despite what you may have heard, I AM alive. Now that all that wedding stuff is out of the way I can get back to the grind stone so to speak. It's a good time to get back into the project because it's started snowing ahead of schedule this year.

Due to circumstances beyond my control it looks like I've finally, for sure this time, lost my working space in my dads garage...unless of course I can finish the job in an 8'x10' corner. I've got a couple of offers for shop space but all our out of town and I don't have a car yet for winter. If I can find a winter beater I should be able to take up one of the offers and move my tools and bike.

In the mean time I've started carefully planning just what needs to be installed, what needs to be fabricated, and what I might still have to buy. The good news is that I have nearly everything I need. The bad news is there might be a few things I'm still going to need to fabricate and without knowing where I'm going to be doing the work, I may end up having to hire that work out...more money, blah!

I've also lost my cheap ass Mig welder...it was only borrowed from my uncle. He's bought a Willy's Jeep and needs it back so he can start restoring it. I haven't finished plugging all the holes in the exhaust, the dump, or the BOV elbow flange I built so I'm either going to have to take it to a welder or take my chances with high temperature exhaust cement...I'll likely just use JB Weld for the intake; I think it's good up to 500 degrees F.

So long story short: It's not going to be an easy re-start but at least I'm confident that I'll complete the job this winter one way or the other...Spring is at least 6 months away which is plenty of time.

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: dtechnologies on December 07, 2006, 11:40:15 AM

Hey everybody. It's been a long time but I'm finally starting up the project again. Between work, getting married, and a pile of other things none of you care about, it's been way too long.

Right now my bike is packed into the back of the garage so deeply you can barely see it:
(http://static.flickr.com/121/316512035_e859450f28.jpg)

Though between my birthday and a very nice present from my parents as a bachelor present, my toolbox has never been nicer:
(http://static.flickr.com/105/316512198_79f4cfedfe.jpg)

Since it's nearly impossible to get in there to do anything, especially since my dad bought 2 snowmobiles, I've turned to getting the Engine Management Computer built and tested as I can do this at home.
(http://static.flickr.com/105/316512757_18c40f30de.jpg)

As you can see there are a lot of holes and not a lot of components. This is the beauty of this design. This board can do so many things it makes ECU's like a MOTEC look basic and over priced. Just by using different components, I can customize the board to suit any situation.

This is the board as it came from the UK. I was worried that the group of Open Source guys that develop the software and circuit boards for this project will have upgraded since I bought the kit over a year ago. I was on their website just last week and I went to the 'requests' section of the wiki to see what might be added or have been added. The message was clear. Nothing is planned because the board can already do everything.

The good news is that to do what I need, not all of those little holes need to be filled with components. When the board support 16+ cylinders and 20+ injectors, EGT sensors, and a pile of other features I'm not touching, the board will need surprisingly few components. Just some driver FETs for the 2 coils and for the 4 injectors, the MAP sensor (which is mounted right on the circuit board and supports up to 30 psi), and some miscelaneous components.

When done, the board will be set up as follows:

Drive 4 injectors. Semi-waste. Squirt 2 cylinders at once. Each Cylinder will get a squirt at TDC.
Drive 2 coils. Wastespark. Same as with squirt, TDC will get spark wether on power stroke or not.
System will re-use the OEM Throttle position sensor.
System will re-use engine temperature sensor.
System will re-use crank trigger and will not use the cam position sensor
System will re-use IAT sensor.
RPM triggered digital output will be configured to control air shifter to act like an MPS Autoshifter
Unlike the OEM electronics, fast idle will be automatic.
ECU will control cooling fan. I'll custom tweak the fan to run as often as needed.
ECU will control a nitrous solenoid or similar device as a fully mappable PWM boost controller
Idle speed will be controlled dynamically by advancing and retarding ignition
Input from Wide Band O₂ sensor will allow ECU to re-configure it's own maps on the fly.
Input from WFO throttle switch to prevent full boost unless throttle is Wide Fucking Open.
Increased redline. I haven't decided how high to go but likely 12k or something like that.

I haven't decided if/how I'm going to use the ECUs capability to incorporate up to 2 EGT sensors and other inputs/outputs. Possibilities include monitoring fuel pressure to include fuel pressure drop failsafes, generic input switches to put ECU into a crippled rain mode like the new sport bikes have, adding a knock sensor (The ECU supports up to 2. Though tuning a knock sensor not designed for this engine is something I'm not sure I want to get into), and so much more!

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: Airbeast on February 11, 2007, 10:41:17 PM

Great Job so far man!

Your project was one of the inspirations for me to do mine. I hope you get it done soon now that you're so close.

By the way what ECU is that?

I'm using the megasquirt in mine which seems almost the same as yours but not. Has all the same features and opensource. How much was yours and where'd you get it from?

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: Busafied™ on February 12, 2007, 07:38:19 PM

Quote from: Airbeast on February 11, 2007, 10:41:17 PM

Great Job so far man!

Your project was one of the inspirations for me to do mine. I hope you get it done soon now that you're so close.

By the way what ECU is that?

I'm using the megasquirt in mine which seems almost the same as yours but not. Has all the same features and opensource. How much was yours and where'd you get it from?

I believe it is the Megasquirt if I recall correctly :wink:

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: Airbeast on February 13, 2007, 11:12:06 AM

hm...his board looks completely different than mine.

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: Busa Quick on February 13, 2007, 11:50:47 AM

In earlier posts he said that electronics was his favorite thing to work on. He also mentioned the Mega Squirt but, talked about modifying it to his own specs.

Mark

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: gsxturbo on February 14, 2007, 12:35:15 AM

I think its a VEMS
http://www.vems-group.org/

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: gsxturbo on February 14, 2007, 12:38:03 AM

Its like an offspring of MS i think, they use the same tuning software

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: dtechnologies on March 23, 2007, 07:13:17 PM

Quote from: gsxturbo on February 14, 2007, 12:35:15 AM

I think its a VEMS
http://www.vems-group.org/

You're right it's the VEMS board. V3.

Sorry I've been away so long folks but getting back on the horse has been tricky since getting married.

I'm all ready to get things rolling this weekend again. The weather is nice here but there's still snow on the ground so I've got a bit of time left before I'm wasting summer.

I may have said this before but things are going to get quick and dirty here. Getting this pig running is top priority so we might not see any street legality right away. If it only sees the track this year, I'll be fine with that considering it's been such a long time coming.

I've had a lot of time away from the bike to think on how I'm doing things and have some good ideas...mostly related to the VEMS unit itself. It's just so damned flexible I'm trying to decide which features to include and which not to bother with. I'm definitely going to be taking advantage of the automatic fast idle, wide band O2 sensor, and all the conveniences like that but I haven't decided on things like traction control, anti-lag, automatic boost control, blah blah blah. I'm also working on linking the box to my computer via bluetooth.

I should have the box at least talking to the computer this weekend via the Megatunix software designed for the megasquirt.

I'll be sure to take some pictures in progress so you guys can see the guts as they're being assembled.

Thanks again for the support in the past...I likely wouldn't have made it this far without you.

Dave

Title: Re: The Frankenbusa Saga. No, I'm not dead.
Post by: reaper0995 on March 24, 2007, 02:28:30 AM

Quote from: dtechnologies on March 23, 2007, 07:13:17 PM

I've had a lot of time away from the bike to think on how I'm doing things and have some good ideas...mostly related to the VEMS unit itself. It's just so damned flexible I'm trying to decide which features to include and which not to bother with. I'm definitely going to be taking advantage of the automatic fast idle, wide band O2 sensor, and all the conveniences like that but I haven't decided on things like traction control, anti-lag, automatic boost control, blah blah blah. I'm also working on linking the box to my computer via bluetooth.

one thing that might be kinda cool is if you make a whellie based boost controller.... like have a switch that you can turn this function on, and when the bike lifts the forks so high, let the boost stop raising until the fork drops a tad..... just a thought :thumb:

Title: Re: The Frankenbusa Saga. Holy crap I'm still here!
Post by: dtechnologies on March 24, 2007, 09:54:44 AM

LOL. I've totally thought about that Reaper. Sorta like the wheelie controller you can buy from Schnitz.

If I were to do it, I wouldn't want to futz with switches and wires on the forks, I'd likely try to use some sort of tilt sensor like an accelerometer that can measure rotational forces or a proximity sensor that can tell when the ground is trying to get away ;)

The nice thing about the ECU is that I can add stuff like that later. Right now I just want to get it running and on a dyno.

Dave

Title: Re: The Frankenbusa Saga. Holy crap I'm still here!
Post by: dtechnologies on March 26, 2007, 07:49:31 AM

I've been doing my homework at the website trying to play catchup so I can get the engine management computer put together and operational. I've learned that since I bought the unit, they've upgraded to a new version. Unfortunately I can't upgrade but I can get some pieces to enhance what I have. I'll have to wait for them to get here from the UK but it should really improve things without having to modify the board later.

The one part I'm looking forward to is their new 'Power Flyback' daughter board which enhances the onboard flyback circuitry. It's basically a daughter board whith 72 diodes on it that allow the flyback voltage to be increased (more voltage=shorter injector opening/closing time). This allows the pulse width of the injectors to be set as low as 600 microseconds. This essentially solves the low rpm tuning issues when large injectors are installed. They've run injectors as big as 1500cc/min on 550cc cylinders with great results.

One other part I've picked up is an immobilizer that's built right into the ECU using an 'iButton'. It's similar to the technology used in new cars with a transponder built into the key only in this case the transponder is a small metal button like a small watch battery. You press it into the socket and voila, the bike won't start without it. And it's all built into the ECU circuit board so there's no bypassing it.

The last thing I ordered was a serial bluetooth module from sparkfun.com I'm going to connect it directly to the serial connections on the ECU motherboard and run the antenna external to the case. It's a Class 1 Bluetooth 2.0 device so as long as there isn't any interference, I should be able to program, monitor, and datalog anything from up to 330 feet away.

I had planned on digging the bike out and getting back into it this weekend but unfortunately I had some car issues I had to deal with so no updates there I'm afraid.