SuzukiHayabusa.org
MEMBERS => MEMBER PROJECTS => Topic started by: reaper0995 on July 16, 2006, 06:28:25 PM
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so....finally i got some parts to start this project! well, my list of parts isn't long, but enough for a few days....
(http://i80.photobucket.com/albums/j196/stupid0995/DSC00595.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC00601.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC00600.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC00596.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC00597.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC00598.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC00599.jpg)
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Give me a call i have my old header off my bike for the 16g if you want it its steel butt its in real good shape i also have the dump pipe for it if you need it might save you some time.
(812)267 9843.
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the turbo before the grinder....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo006.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo005.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo004.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo007.jpg)
holy crap, talk about needing a wrench of sorts to remove TWO bolts.....one broke twice, the other just once....TWO BOLTS!!!
(http://i80.photobucket.com/albums/j196/stupid0995/turbo008-1.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo009.jpg)
and after.....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo012.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo011.jpg)
the before on the gate hole
(http://i80.photobucket.com/albums/j196/stupid0995/turbo010.jpg)
and the port after. looks a little larger in real life, but may yet still decide to port more on this....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo013.jpg)
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also, upon porting of the gate area, i have found a few minor hairline cracks on the INSIDE of the housing. the two or possibly three cracks are not visible from the outside of the turbo, thus i think that the turbo should be just fine. any thoughts? the cracks are right on the lip that the gate hole 'opens' from the normal path of the turbo, the "T" if you will in the housing.
another thing, since i have removed my gate and flapper, there is still a hole in the flapper's place. how should i go about pluging the hole? its maybe 3/8 diameter. i thought about welding it shut, but i dont think this would work because i'm pretty sure its cast IRON, not cast STEEL. a guy at our work tried welding cast iron, and no matter how clean the weld, how deep, how this or that, it just couldn't really get it to work....afraid i may have the same problem, but his welds did hold, just not under a lot of stress.....and this makes me wonder if it could work because it isn't really getting torqued on. yea, yea, it is getting stressed. i mean after all, it would be on he hottest part of an engine setup, and exposed to a huge range of operating conditions, but not any real direct force will be applied on it. or do you think that tapping it and plugging it would work best? if so, what do i use to 'locktite; the bolt? i mean, i think normal locktite lasts to like 400 degrees (???) or something, but turbos run over 1000+.....hmmm
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took apart the FMU to check out the shim thing that seems to be a looming problem so some....not quite sure if this is ok or not, but it lloks good. there is no real dimple ion the middle, none at all. but there is a little crinkle on the edge that you can see in the picture. looking at the way the unit works though, i'm guessing it wont really be a problem, but it might be worth replacing anyways....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo014.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo015.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo016.jpg)
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Good stuff.
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trying right now to get a new shim.... but in the mean-time, some parts showed up! got an external gate, 3 fuel rail inserts (i think i will only need 2, but why not just in case?), block off plates for oil cooler, and an oil drain return line.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo017.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo018.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo019.jpg)
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reap...dennis has an oil block off plate that is tapped for the oil supply for the turbo. it keeps you from having to mess with the oil pressure sensor. very cool, imo. i bet you could drill and tap that block off plate to do the same job.
get to work already!!!!;)
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get to work already!!!!;)
sorry :wink:
been riding it too much to tear down....too many nice sunny days here to stop riding! but i'll do some more work tonight though to help speed along the project...
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ok, so i got most of the plenum mocked-up. just need to finish off the last velocity stack and the weld the stacks onto the plenum. got the bolt i will use for the MAP sensor and now i just need to cut some end caps and decide on how large of intake piping i will need....
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(http://i80.photobucket.com/albums/j196/stupid0995/turbo020.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo021.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo022.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo023.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/turbo025.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo026.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo027.jpg)
looks like a good fit, nice and close for the best welds!!
(http://i80.photobucket.com/albums/j196/stupid0995/turbo028.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/turbo029.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo030.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo032.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo033.jpg)
looks about the same height as the stock plenum, but it is a little shorter actually. will probably trim up a tad to make all the runners same length. now they are like 1/16 or 1/8 at worst from one another.
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hey, on that oil cooler block-off to be used as a feedline, i take it the restrictor still comes out, but which one is should i tap it from? the one on the front of the bike, or the side nearest the oil-pressure sensor? the one near the pressure sender is my guess...
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yes, restrictor still comes out.
the oil feed is on the side of the bike by the oil sensor....like u thought. ;)
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so, got the plenum MOSTLY finished....would have been done, minus paint or coating....BUT, like an idiot, i welded the bung for the sensor right where the gas tank shuts....so, now i have to go back to the store and buy another bolt, grind off the coating, anf drill another hole and weld on the CORRECT side, so much for trying to clean up the front side......
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(http://i80.photobucket.com/albums/j196/stupid0995/turbo034.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo035.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo036.jpg)
and there is the lucky sensor..in the unlucky location. stupid mistake is gonna cost me a good 45 min to go the store and drill and...etc. :evil:
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thanks once again to busamagic who sent the new shim and very proptmly i might ad.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo037.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo038.jpg)
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and now i begin the oil feed and return lines. the return line is gonna be a little tricky, as the place the i have found that sells the return fitting is out of stock ad has been out for severl weeks. and given that the only thing that i can weld with my welder is steel, which will corrode, my only real choice besides finding another supplier is to make a 3/8 thick peice of aluminum plate that i will have to tap out for a large fitting to go into then slide the hose over that fitting. not my first choice, as there shouldn't be any restrictions in the retun line, especially that close to the turbo.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo039.jpg)
the fittings on the hose are not situated permanently, but are just lightly screwed on. i will adjust the length later as it is put into place. will probably need to get some 90 deg. fittings to allow for a drastically shortened feedline.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo040.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo041.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo042.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo043.jpg)
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What made you decide on the plenum design?
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i thought that using a 3in tube would limit the amount of welding i would have to do. but on the other hand, doing it this way proved to kinda suck.... making each one of the runners contour was kinda time consuming, enough so to say that an extra 15inches of welds would have been a much easier method. the way the ghetto looks is really cool and i totally would want to do one like that, but i am trying to go for simplicity, and i am not going for more than like 250-275hp. hahn and mr. turbo use log style manifolds, as does the MCxpress. mine may not be as bling, but should do a descent job. it not, i can always make a new one, as this one only took like 6hours (two evenings).
just out of curiousity, is there something that you notice that wont work with the way i have it setup?
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so, did a plenum pressure test today....can you guess which one blew out first? place your vote here:
http://www.suzukihayabusa.org/forum/index.php?topic=79812.0
(http://i80.photobucket.com/albums/j196/stupid0995/turbo044.jpg)
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and it blew out the sprite can!! aw, the sweat taste of victory (no leaks)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo048.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo052.jpg)
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ok, so these sleeves were REALLY hard to find....went to every place i couls possilbly think of. couldn't find it. THEN, when all looked hopeless, i saw a performance shop open by chance...went over to see if they had anything that was 1.5 inch ID and about 1/8 inch thick. i only needed 4 or so inches, since each sleeve will only be 3/4 to 1 inch long. he had a peice laying around that was 7 inches long, 1.5 inch ID, and 1/8 thick walls!!! gave it to me free of charge too!! well, this is how the sleeves looked after cutting and grinding them, notice how nicely they fit!!
(http://i80.photobucket.com/albums/j196/stupid0995/turbo054.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo055.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo057.jpg)
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the got onto some flange work.. had to grind out a little of imperfections (didn't drill as closely as i ould have liked). took a little while. then i also had to cut them out of the large peice of steel. i pretty much finished one, the other i will do tomorrow or the next day.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo058.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo060.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo061.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo063.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo065.jpg)
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then decided to port a little more on the gate opening....looked a little small in lou of the size of the external gate i have, so why not?
(http://i80.photobucket.com/albums/j196/stupid0995/turbo067.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo069.jpg)
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and then this is just a 'here is the kit thus far' pic.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo070.jpg)
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Looks like it is just a matter of time and you will have success. You look like you are doing some nice work overall.
Mark
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yeah, so i had a few extra minutes today, and all the stuff, so i made (or started..) some exhaust flanges today....BUT, i burned my hand by grabbing the metal after cutting it part way, and so i have to stop for tonight :evil:
but, here are the flanges thus far:
(http://i80.photobucket.com/albums/j196/stupid0995/turbo073.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo074.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo077.jpg)
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edges ended up a little thinner than i would have liked, but it isn't going to be that big of a deal i dont think. still plenty of metal to hold on the exhaust IMHO. if not, then i can always weld on more or make new flanges later....
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yep, and here is my gate apart so i can check out my spring.....but i am not sure on which it is or isn't....anyone know for sure? i WANT a 6psi, or 4 to 8 would also work....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo071.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo072.jpg)
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ok, so i got over my hand burn :wink: , and got my flanges mostly done. need to drill holes for header bolts out from 1/4 to 5/16 or so. too small.... any-how, they need some grinding to smooth them out, but here is a rough mock-up of what i am kinda making thus far...
(http://i80.photobucket.com/albums/j196/stupid0995/turbo080.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo081.jpg)
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funny how i am gonna have to make 4 pipes that are 1.5 inches diameter EACH adapt to ONE hole on the turbo that is 2.125 inch diam. well, happy welding and grinding is in my future :lol:
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It looks like you are going old school on the header system, you gonna run a straight pipe connecting all the exhaust tubes to the turbo??? I got a series of magazines and books that were published on how to turbo motorcycles, with graphs and stats if you need any info let me know. I would never have the guts to at it myself. There is an article on a do it yourself set up done on a katana with blow-through carbs, the guy who wrote the books realy knows his stuff. They have a pic of how its done, you run the tubes straight down the front of the motor pointing at the ground, take one tube lay it horizontaly and cut four holes the diameter of exhaust tubes and weld the to the horizontal tube. Then you cap off each end of the horizontal tube, and run one pipe out of the middle to the turbo. The old indy cars used to run this type header and it was called a log style system.
(http://i87.photobucket.com/albums/k146/unit176/IMG_0970.jpg)
(http://i87.photobucket.com/albums/k146/unit176/IMG_0970.jpg)
(http://i87.photobucket.com/albums/k146/unit176/IMG_0967.jpg)
(http://i87.photobucket.com/albums/k146/unit176/IMG_0965.jpg)
If you are interested I'll see if I can have all the do it yourself articles scanned and email them to you.
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thanks man, but i am any doing a log style INTAKE man. my exhaust will look kind like the normal systems.....hahn, ghetto, etc. i was just saying it is gonna ba a little time consuming to Y all those pipes to such a small hole when each pipe is almost the size on the hole itself. what is the name of te book though? i have a few old turbo books but havent really read all of them yet. that TURBOCHARGERS by hugh McInnese or something is a person fav of mine, it tought me how to do all the turbo calc's and stuff.
thanks again, but i dont think i will need them at this time.
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and just a minor update. got a second busa fan in so i can mount that up and wire a switch or a constant run when on....can't decide yet. but also got my hks style BOV. yea, its not the real one, but i have heard a few people say that the chinese stuff aint that bad after all....at least the non-turbo itself stuff. if it is no good, it was only like $50 shipped!!! wow! and it wont cause my motor to blow either if it fails....i dont know how it could fail though.. but it lookds BLING!
(http://i80.photobucket.com/albums/j196/stupid0995/turbo082.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo083.jpg)
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only one problem with the BOV....i have a mild plenum, and the flange they sent was aluminum :(
guess i will have to order another....gonna cost a whole lot of like $5 or something :lol:
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so i got my clutch slave support as well as some other trivial items in the mail the other day....lowering clamp, dogbones (3 hole), extra rad. fan....etc. installed the slave support because i have been sporting the heavy duty springs for some time now, like 2 months of daily driving and track days :D no problems or even cracking, but it is definately not gonna give me any troubles from hear on out.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo084.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo085.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo086.jpg)
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Dude your a beast! :twisted: Nice work!
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Cool man, god job. You know they sell this fancy product at the parts stores called degreaser, does wonders on that there engine. :D
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Cool man, god job. You know they sell this fancy product at the parts stores called degreaser, does wonders on that there engine. :D
:D i know, but i did one better...got a new gasket....only problem is, i put the old one back in because i thought i was gonna have it dynoed BEFORE the gasket came in. so now i have a new gasket OUT of the bike and new oil and filter with like 2 miles...
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ITS ALIVE!!!!
well, kinda. i started it up a few times and it will idle, sorta. runs kinda crappy, but has no adjustments and zero tuning. new pump and fmu, so i didnt think it would run good anyways. but it ran enought o run up the block and back and check for loose fitings and leaks and the sort. all looks good :twisted:
going to drop off at dyno shop tomorrow, but they cant dyno it and tune it until next week when tey put in the PC3, so i will have to wait a few more days, but all in the sake of thy turbo. WORTH IT!
so yeah, if ya haven't figured it out yet, i have completed the buildup and am now waiting for the final step: tuning. i will have to go back ad adjust the intake track, since it will stick out beyond the body work, but i really want to get to the track before it closes....on the 11th of Oct. so my plan is to have it dynoe by mid/late next week, ride it a little, then drive it up to see some friends about 70 miles away and back, then go to the test and tune a few days later. see, i am a little afriad that my buds will drive down to see me at the track, and some stupid piddly thing will keep me from running, and they will have driven over an hour for nothing. so i want to be sure that it will be ready to go when the i am at the track.
enough talk already.here are the pics 8)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01152.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01154.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01155.jpg)
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you can see the heat on the mild steel here from the heat cycle i put it trought the other day (to check for leaks and crap..)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01156.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01157.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01158.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01160.jpg)
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and the builder and the beast.... :twisted:
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01161.jpg)
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and i did drop it like 2 inches or so. need to lift it back up in the rear so it wont tip when kickstand is down....sits just past level as is right now...me no likey. on the plus side though, it looks WAY cool low like that. my mom came and checked it out and she could put her feet flat on the floor and a little bend in the legs!
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and taking a step back...here is the buildup ya missed :wink:
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01061.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01066-1.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01067-1.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01068.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01070.jpg)
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and here i got the wastegate to dump out the opening of the fairing....then i had to shorten my header like 3/4inch....SO, hope it will still look good when farings go back on...
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01090.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01093.jpg)
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and the dump being created...
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01096.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01097.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01098.jpg)
MAN!! talk about signature turbo look, i am was so excited to see this look on MY bike :twisted:
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01102.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01104.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01110.jpg)
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fuel rail assembly
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01119.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01120.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01122.jpg)
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and the oil restrictor removal
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01143.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01144.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01145.jpg)
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and now the new plenum intake....was 1.5in, now 2in. should help flow and give less restriction to harder bends in the intake track.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01146.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01147.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01149.jpg)
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and this is the header being shortened. it was a little long and made it so the oil would be at the turbo's level...not good. so, some trimming later, solves problem! 8)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01135.jpg)
BEFORE:
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01102.jpg)
AFTER
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01112.jpg)
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and here is the photos of it before i dropped it off at the dyno, should be ready in next few days
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01162.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01165.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01164.jpg)
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oh yeah, and that was the FIRST and LAST (hopefully....) time it should see a trailer :twisted:
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Good on ya for having a go and doing it yourself :D I wish more ppl did
Gary
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Good on ya for having a go and doing it yourself :D I wish more ppl did
Gary
thanks man. me too, its always cool to see some hoe welding and assembly. i tried to take photos of stuff people hadnt yet, like the oil plug removal. hopefully mre people will start getting more creative with these bikes as their prices begin to fall...
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yeah, so went to the dyno shop today...and some good, some bad news...
the bad: my rail leaks out of the O rings, so i will have to get some new ones. My fmu (i think) wont releive pressure, so i will have to take it apart and clean it and find whether or not i need a new one. hopefully not. my gate spring was a little lower than anticipated, so i had to get a boost controller, but luckily a local shop had one for $20 that i got already, so that wont take but a minute to install.
the good: overall it worked. they couldnt dyno it because of the bad, but the tubes didnt blow off, looked very promising. so i am a little bummed about today, but in high hopes of completing it soon to drive the hell out of it :twisted:
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might have something to do with my VIN ending in 666.... :!:
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been a few posts since i have had photos....so, i got some paint the other day to paint my bike FROM blue/silver to blue/yellow. my left fairing was damaged by previous owner, so here is the scrap-down and goal....
THE GOAL:
(http://i80.photobucket.com/albums/j196/stupid0995/by3.jpg)
AND HOW TO GET THERE....
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01193.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01194.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01195.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01196.jpg)
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YIIIPPPPPPEEEEEEEE!!!! i drove it today, AND buit BOOST!!!! just made like 4 psi, had 1/2 mix of race gas (112) and 10% extra fuel on pc3. rode it just a little bit. full throttled it on the way back home in first gear... :bah: it started to power wheelie a little at like 5-6k rpms, then shot to 9 grand in a heart beat and power wheelied up like 18+inches!!! (probably like 2 ft). from before it never power wheelied that low, like maybe around redline, and definately when i shifted. it power wheelied like A LOT! and not even close to redline.
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congratulations reaper!!!!!!!
i cant wait to see that color scheme.
that is going to look sweet!!!!!
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ok, so checked out the O ring problem....got some new ones on order (still), but in the mean time i happened to find some ones at a local hardware store that did fit. cost was like $2.51 for 8 of them, $5 EACH at the dealership....crap IMHO. but i put one in gas before i put them on to make sure they wouldn't dissolve. and nope, was still there fully intact when i checked on it a while later. THEN, put them on, put everything back together...and it STILL LEAKED!! i was like AAAAAHHHHHH!!! so i had a huntch that it may not have ever have been the O rings, but perhaps the brass bungs. yep, seemed to solve the problem.
and i think the FMU is fine. did several tests (bicycle pump and boost gauge....), and i think it wont have to go in the garbage :thumb: so now i am waiting to get a friends wideband, then i can weld a bung on the DP (got two bungs and a plug for $5 from MIDAS! thanks guys, you are allright! i also couldnt find them anywhere else, so thanks for having some IN stock). then i can test ride it a little more.
also got the ghetto 10psi map from PINKY. thanks man! but i must have a different PC or something....i had to manually insert the numbers into a map because it wouldnt upload. some compatibility issues. no biggie. just look at the one and type in the other :wink:
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oh yeah, will get some photos of this up soon, but i have found a new way to do the intake track that should remove my earlier problems of fitment in the fairings. got the left one mostly done, but still have a little more trimming left. shouldnt be too hard, just got tired last night and couldnt finish.
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is it already painted or do you still have to paint it?
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still need to paint, but most is prepped up for the most part. i dont want to start painting until i finish fitment, just in case i have to sdd a little here and there... :wink: the holes and broke offf peices are almost finished, just need to fill one more peice in on the left fairing and it will be ready minus final fitment of the filter.
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Looking very good - You have perseverance :!:
You are removing the decals... right :?:
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01194.jpg)
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You are removing the decals... right :?:
oh yeah, just need to borrow a heat gun or just use a hairdryer....
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hey, so an update.....
gone through like 3 or 4 tanks of pump thus far on just 4psi. yeah yeah, still need to go and tune for 8psi, but it is good for now, that and i am having trouble managing 4 psi due to the cold....lose traction easily enough right now.
got the fairings on and they fit good after mucho trimming for the filter/dump. though i did cut quite a bit more than i needed on the exhaust side....but i took a spare peice i had and molded it back on to some degree. it will be behind the dump and w/gate, so it shouldnt be TOO noticeable. anyways, got some stuff called Plastic Fusion epoxy from home depot and repaired some holes and cracked off pieces. check out the progress...
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01195.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01248.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01250.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01244.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01246.jpg)
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one more thing.... i AM goig to cut off the exhaust so it is a little more flush. like the other kits. i have some o2 bungs around too to put on a wideband, but i seemed to have lost them. sucks because i already borrowed my friends wideband and now i cant find the bungs to put it on :(
oh well, still plugging along!
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01252.jpg)
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Awesome project man!
Max
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Beautiful.
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Lookin good Reap- Keep it up 8)
Only thing I tried to avoid with my 3" exhaust was hackin too much from the body vent-
So I had some aluminized Exhaust kicked at a muffler shop, to line it up a bit more.
(http://busafied.com/boostafied/dump2.jpg)
(http://busafied.com/boostafied/tbright.jpg)
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i actually didnt HAVE to cut out too much fairings for my dump pipe and wastegate, but i DID anyways :lol: :lol: turns out its a lot easier said than done.....but i had a good sized peice of fairing left over from the airfilter so i trimed it up and epoxied it back into the large gapping hole. oops.
i actually tred to line mine up so i wouldnt have to cut out my w/gate hole, but then i had to shorten my header like an inch so my oil would drain correctly. still sits a little lower than i would like, but hasnt given me troubles yet. next one i make i am going to really take my time on turbo placement and really get a good place for the filter and dump pipes and the sort.
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I got lost with all the post, did you dyno it yet? Good job!
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minor update....got some o2 bungs...then lost them of all things :lol: oh well, got some new ones and just looking for some time to get over to my work to weld them on the dump. i was looking around at where to put the bung and all, trying to make the sensor as far away from the turbo as possible in my like 12 in long dump pipe. and trying to get it to clear the w/gate pipe and the engine itself. turns out there was a nice and tidy location between all of it after all.
oh yeah, and i still have to put on my new radiator hose. turns out my old full HMF system barely touched it for who knows how long and dried the tube up. well, one day i was cruisin around and stopped for a second only to see LOTS of steam coming from MY bike :cry: so i turned it off immediately....and looked around and saw the busted tube spraying antifreeze all DIRECTLY onto the turbo!! so it was steaming a TON!! had to get AAA, and, of course, i dont have the "special" coverage that covers motorcycles, only cars :evil: so i had to pay like $90 to get it home that day. sucked. then i tore it down and order the new part. it was gonna take a while since the dealer had to special order the thing. but thats when i looked at the pipe and saw that it was good, just had been heated on the one part. so i cut out the cracking part and put in a piece of aluminum for the time being. works good but now i need to drain it again and put in the good stuff :thumb:
amazing how many problems can be solved by turboing, eh??
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amazing how many problems can be solved by turboing, eh??
Ya like those pesky Rod bearings/ :P
http://www.suzukihayabusa.org/forum/index.php?topic=59674.0
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well, time for a minor update. snow has lengthed anything being done for some time as well as mileage. i had welded the o2 bung on some time ago, but no time to put the bloody thing back on. just got it on and now looking for place to mount the o2 gauge/box thingy. its about 5/8 inch tall, 3 inch wide, and like 5 inches deep. i think i may be able to rig it up for now on the tree next to the boost gauge. this will be my insurance until i can get it fully tuned.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01600.jpg)
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and another thing too while i'm at it. nothing new, this part has been done and not touched in months, but i realized i had no photos of it finished under the tank. well, here ya go 8)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01604.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01601.jpg)
adn the fuel system if you can see it well enough...
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01602.jpg)
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Looks pretty good for a home built! What A/F meter are you using? If you get around to how about a picture of the that.
Can't wait for the dyno results.
Mark
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and the wideband is installed.... ghetto/temporary style too :lol: just wanted to make sure i wasnt gonna run lean or nothing tomorrow when i ride it for the first time since thanksgiving (snow storms like crazy, still have 10+ inches of snow, and been there for like 50 days...)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01616.jpg)
and yep, you guess it!! it is duct tape and STRING holding it on!! :D hey, better to be ghetto here and be safe on the rest of it, right? i half wanted to be ghetto because i want to do a logger and until then, i dont want to do anything permanent that i wont be able to undo once that goes in, like drilling holes and mounting tabs, etc.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01618.jpg)
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AHHHH!!! so, my turbo starts to smoke from time to time now.. rode it just fine about 80 miles to visit some friends, no problems. rode it home, nothing until i hit traffic about 10miles from my house. it smoking blue and a LOT!! thought maybe i had stopped to hard and the oil backfilled the turbo because it does sit a tad low in the bike (but still above oil level). so, i let it sit for a few days on a slight uphill slope and took it for a spin..... rode fine! then continued to drive it around and then it smoked again :evil: not at every light though would it smoke, and for no set length of time would it smoke. sometimes none, sometimes a lot, sometimes for a long time and others just a second. ??? looked around and seems like i need to do the following:
1 raise front more when parked.
2 put restrictor in feedline
3 if this fails, make a new header to lift the turbo up some more
4 scavenge pump
and, OF COURSE, pics:
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01934.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01936.jpg)
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and the solution: well, i hope :lol: this is my oil restrictor i made. the local performance shop didnt have a specific oil restrictor part, so i had to take a NOS line item that was used to put on a guage for and put a bolt in it to tapper the oil flow. testing to follow.....
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01937.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01938.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01941.jpg)
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did it work?
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Had it on the dyno yet?
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yeah, more pics!!
ok, so i FINALLY made a gauge bezel and switch bezel. there are two switches, one is for the second fan, the other is for the lanyard item. the lanyard thing is the item you have to have when racing where you pull the lanyard out and the bike dies, but when i drive on the street, i dont want to have to carry around a stupid lanyard and worry about someone jacking it if i forget to take it out or something. the gauges are obviously the boost and the fuel pressure. the tach is completely visible and the mph is a little near like 10mph and 200-220mph, but whos gonna look at the mph when going that fast anyways :lol:
carboard template, then aluminum sheet to bent gauge bezel. switch plate was made from angle iron.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02204.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02205.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02206.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02208.jpg)
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and this is how it looks so far... still need to finish the bolts on the bracket (lost mine, need to buy more, haha), switch boost gauges, plumb lines to fuel gauge, and wire the switches... nothing too hard, just need the time. oh yeah, and the lanyard thing with the switches (took of the kickstand switch cause IT was pushing the kiskstand down and killing my bike on te road, no dice there!) but the kiskstand kill switch will become my lanyard pull switch.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02214.jpg)
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the seat has actually been done for a few months now, just didnt really like the way it looked when it was done.. though it may look a little less intense when the bike is yellow or..?? still not totally sure on colors... either stock, blue yellow as before photo shows, or pumpkin orange... still need to decide. most likely yellow because the paint is here and waiting (ie free!). so... nuf chit chat!
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01287.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01288.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01289.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01290.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01291.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01061-1.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01293.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01295.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01296.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01298.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01299.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01301.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01304.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01305.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC01306.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01311.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01312.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01313.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01314.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC01317.jpg)
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keep in mind that i am not by any means a PRO at sewing :lol: i am what i would consider a "high end" upholsterer, but not good at sewing...lol, i know. how can that be?? i worked with a really AWESOME upholsterer that had taught me how to do upholstery, so the panels i set up would be sewn by him, and back to me again. learned a LOT doing that (4 years+), but the business has since moved. :cry: but times change.
anyways, this was my first motorcycle seat that i had sewn myself (and still the only one i have done. i have flat wrapped several including my friends, but in solids).
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and thank you to Scarry Jerry!!! just got in the dash panels, and now i can start on making some carbon fiber inners!! i will either make a mold out of these and then make the inners COMPLETELY out of CF, or i will use them as a base and just lay the CF and COVER them with it. either way, shouldnt cost too much and even if they are just covering the old plastic, will still look bomb 8) but before that i have to patch the holes from scary's bike :lol:
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02221.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02223.jpg)
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where did you get the flat blue shimmer seat fabric?
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where did you get the flat blue shimmer seat fabric?
we had some from another install that we did on a car. i will try and find out where it came from (which supplier) and get back to you. i may be able to get it for you because most places dont really sell to the general public (wholesalers). i really like that shimmer blue though myself :thumb:
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just got in my carbon fiber!! looks cool too. it is pretty soft and yeah, is just like cloth. i mean, besides the duh reastion to carbon fiber CLOTH being like cloth, i was expecting it to be more stiff, or more this or that, but nope, just normal. well, it does fray EASILY at the edges...
enough witht he chit chat, here da pics yo
i think it is like 36 x 48 or so. enough to do my dash inners and maybe 2 more sets IF i feel up to it.... better start getting on my good side :lol:
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02271.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC02272.jpg)
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can i be your friend? :lol:
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shhhhiiiiaaaatttt... I pay you to make me seat covers....
:D
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so i decided to give the whole carbon fiber thing a little test. i got some FIBERGLASS resin and WD-40 as my contact and release agent. the carbon fiber peices i am doing (dash inners) are NOT structural, so i dont think that having the best of the best epoxy resin will be needed, thus i got the fiberglass (like $9 at ace hardware).
the CF is VERY DELICATE!!!! it looks like the way they weave it the fibers themselves are almost like they are layed FLAT beside one another, and when you touch them, they tend to "collect" or "roll." almost like hair, where you may have it straight (parellel to one another), then if you begin to rub your fingers it tends to bunch up. hard to explain, but long story short, the more i fiddled with it the larger the holes became in the part that you could kinda see-thru.
all the parts to do this: vaccuum, garbage bag, scissors, resin/hardener, obect to test on (bottom of bottle), wd-40, foam (to allow air to escape around carbon fiber), and of course carbon fiber cloth.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo087.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo088.jpg)
cutting the carbon fiber to size
(http://i80.photobucket.com/albums/j196/stupid0995/turbo089.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo090.jpg)
mixing hardener into resin
(http://i80.photobucket.com/albums/j196/stupid0995/turbo091.jpg)
wd-40 onto the foam so it can be taken off after resin has cured
(http://i80.photobucket.com/albums/j196/stupid0995/turbo092.jpg)
applying the resin to bottle
(http://i80.photobucket.com/albums/j196/stupid0995/turbo093.jpg)
laying the carbon fiber on the resin
(http://i80.photobucket.com/albums/j196/stupid0995/turbo094.jpg)
carefully applying the carbon fiber to the bottle
(http://i80.photobucket.com/albums/j196/stupid0995/turbo095.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo096.jpg)
just so you are on the same page as me (putting the foam on the CF then inserting into bag)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo097.jpg)
after the vaccuuming....some air got in, but it looks like the carbon fiber was already pressed to the bottle, so should be fine....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo098.jpg)
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well, the carbon fiber bottle worked....kinda. the foam did NOT work well. it did press it firmly, but it made the resin have a grainy finish and left little bits of foam behind. the bag, however, did touch some of hte carbon fiber it appears and those parts where it touched worked well: or it touched it and then the air released it to not form bond. in any case, it was promising enough to start on one of the pieces.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo104.jpg)
for this piece (only did one thus far), i actually did NOT use a bag at all. the peice was just too ackward to handle and put in the bag, so i just kept applying the resin with my finger until the CF took the shape of the part.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo105.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo106.jpg)
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and another minor update....
i have the whole kill switch lanyard thing working as well as the actual switch to deactivate it (the actual switch just connects the leads so when i drive around town i dont need to use the lanyard. DAILY DRIVER dont forget!!)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo112.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo113.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo114.jpg)
and i was looking through and i realized i hadnt posted how i made my bar ends. i first made the prototypes here on my lathe i have. i orignally made these for a mini-chopper i made when i was in high school (3-4 years ago)!! made out of aluminum.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo107.jpg)
then my uncle, who has a machine shop, made a set of stainless on a fully CNC'ed machine. here is it next to the prototype. by the way, thanks to my uncle Jim!! he actually made these for me as a suprize gift!! thanks!!
(http://i80.photobucket.com/albums/j196/stupid0995/turbo108.jpg)
and originally these were made for the mini chopper, and have standard threads. thanfully though, they also had a large recession machined into them so welding an adaptor bolt was pretty easy.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo109.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo110.jpg)
and the final look of the cockpit :lol:
(http://i80.photobucket.com/albums/j196/stupid0995/turbo111.jpg)
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Hint of the day :wink: prep part clean very well now use 3m super 77 spray adhiseive slowly apply the carbon mesh now resin. then resin again sand smooth the clearcoat with automotive paint
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Hint of the day :wink: prep part clean very well now use 3m super 77 spray adhiseive slowly apply the carbon mesh now resin. then resin again sand smooth the clearcoat with automotive paint
haha, i may have to. i was actually wondering about this, namely because it is very much so like the way i used to do interior work (glue the part and apply fabric). hadn't thought it would work on these kinds of things, but i will try a test peice since i already have the glue!!
thanks
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(http://i85.photobucket.com/albums/k74/Shamrock_Racing/100_29791111.jpg)
trust me it works iv done 3 or 4 seat cowls :wink:
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check it out!!!! looks like the adhesive idea is THE way to do it!! i had thought of this a while back, seeing as it is virtually the exact same thing i did with upholstery items in cars, but i thought that the adhesive would not work with the CF. i thought the CF would twist and distort (which it kinda does IF you move it even a LITTLE), or not mix with the resin, or, etc... BUT, it did!! thanks for the help 469, the wholes vaccuum idea really sucked :lol: or didnt...
ok, so here is the run down. you need an industrial strength automotive (upholstery) adhesive, i think most stores like home depot or something carry a similar style adhesive. PREFERABLY spray can, but i dunno if you could really do a "paint-on" style glue, but the spray stuff is cheap. you need the resin (once again i have fiberglass resin, nothing special), a mixing can, brush (wal-mart has these for like $0.25), and of course your part and some carbon fiber.
spray on the adhesive. do light strokes, making sure to be even and NOT to make any globs. you dont need much, but make SURE ALL areas that are to be covered in CF have glue!! if no glue, then the CF will "float" over it and part may not look good or even work.... then take the CF and make SURE that it is straight and ready to lay on the part, begin to slowly work it on, making sure not to let the edge of the CF come close the part, as it will fray and you dont want to run short (i did once or tiwce). and remember, YOU HAVE ONE CHANCE TO DO IT RIGHT!!! you MAY be able to make a SMALL correction, but for the most part when the CF touches the glue, thats where it will be forever, PERIOD. take you time on this step. now, mix the resin and the hardener (read for exact ratios). then take the brush ad slowly begin to spread it over the CF. i found that going diagonal the the weave gave the smoothest brush strokes. make sure that all the "spaces" between the weaves are filled witht the resin. i put on a coat just thick enough to cover the part, but thin enough that once the resin cured, you could feel the weave pattern. i will go back later and either add another layer of resin (brush of course), or try just going straight to clear coat and polishing that to level the surface. i believe that the best method will be to re-resin the part to level the weave, THEN clear coat it and smooth it more. i will experiament and get back on that though...
(http://i80.photobucket.com/albums/j196/stupid0995/turbo116.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo117.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo118.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo119.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo120.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo121.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo122.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo123.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo124.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo125.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo126.jpg)
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just thought i may go ahead and add this in here so that i would have my FULL build diary in one place.... (copied from another thread i started)
this install took me just over an hour (timed) from fairings off to back on again. i have never done this mod before, but had taken apart the clutch before (http://www.suzukihayabusa.org/forum/index.php?topic=70006.0 (http://www.suzukihayabusa.org/forum/index.php?topic=70006.0))....
i took off the fairings, and removed the clutch cover. i left it on the kickstand, and this was enough tilt that there was no oil in the clutch basket area. i have also done the kickstand ground out mod...anyways, took off the out pressure plate and removed the clutch plates, leaving them in order and same direction, so as to not mix them up, not sure if important, but no use in in, right? took of center bolt that holds the inner hub. talk about a pain in the neck! when removing the bearings, they all really stayed together pretty well, so i just made sure to be gentle with them so that i wouldn't have to mess with them and add more work :D. so then i took off bolts from stock clutch cam thingy, then retorqued them with locktite onto the one piece replacement. it said use red, but all i had was blue, so i just put on a little extra :wink:. then i began to reassemble. everthing was going good, until i had to torque down the inner hub retaining bolt. it is at like 68.5 ft/lbs or something rediculous, at least when the bolt threads you are tightening to are not fixed... SO, what to do??? well, i got a large plybar that i got and put it in between two or the clutch spring bolts that i had put on earlier and then tried to torque down. this worked!!!! but i am not sure that i would like to do this one again...the manual shows a special tool that grips the 'teeth' of the inner hub, and naturally, who has one of those just laying around at home? so the plybar to the rescue! anywho, that was back on, did the center punch to ensure it wouldn't loosen (like manaul says to) and the put back my clutchpack. then put back on the pressure plate and install heavy duty clutch springs. ***FYI, the guy i bought this stuff from told me that when you use these for a while, your clutch slave support will begin to crack, and to get a clutch slave support bracket*** now, since i am probably going to put the stock springs back in after i take it to the track, i dicided not to do this, nor did i have the part...so, then it was together again, and i took it for a ride...WOW, it kinda removed that KA-THUNK that a bike makes when you downshift the bike into first from neutral. the clutch lever is a lot stiffer, a little too stiff for long riding in my opinion (or at least in the city, highway is probably fine since no shifting). now there was one thing the guy also warned me about and i have felt a little. if you downshift a little abruptly, it will fishtail in the tinniest of ways. but if you watch it and know that it has this tendency, or even if you don't, it probably won't cause much in the way of problems...unless you downshit hard in a corner, but who would do that anyway? so here are my pics:
btw, the one of the two springs is stock vs. heavy duty (you can guess which is which :D)
(http://i80.photobucket.com/albums/j196/stupid0995/bam001.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/bam002.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/bam003.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/bam004.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/bam005.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/bam006.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/bam007.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/bam008.jpg)
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thank you busafied!!! (from the boostafied project) i got my scavenge pump in yesterday, and took the fairings off in order to get a look at what the whole thig is gonna look like when it is done....
well, i have a few areas that i like and dont like.... it looks like it may be able to go beside the oil pan, kinda where the exhaust normally goes, but i dunno if it will be too big and hit the fairings. i dont think it will work very good in the back, just above the underbelly wing, because it looks like it will interfere witht he wing being installed (just got one finally!!). another probably the BEST place is going to directly under the turbo. there, it has room left to right, up down, front back, you get it. then my oil lines can be short, i can probabaly make a reserve tank really easily, and i can return the oil easy too.. i have 2 locations namely about returning the oil. the first is the oil cap, but i dont want to lose the ability to add oil easily in case i am in the boonie middle of nowhere, so i DONT want to have to use this option.... my BEST option i think will be to put it next to the starter cover... dunno how to describe it, but that cover that the pimp pump goes on, right there is another hole, and when taken off you can see oil and that looks like a good place to drop it off at!! so, that is also towards the front of the bike, and wont be visible when the fairings are on, and doesnt hinder my ability to change oil easily on the go. looks like a winner!! look at the pics, i have one fitting in the location i mean, plus i have a mockup of how i WOULD do the oil cap IF i were to do it that way.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo127.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo128.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo129.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo130.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo131.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo132.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo133.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo134.jpg)
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With the pump mounted using the tab stickign down in front of the ears the center stand mounts to, it was fine-
I spaced my wing down using a few washers on each side, and making some extending tabs to lower the bracket the wing bolts to.
I do not have picks of the bracket I made to extend the bracket down, but isn't hard using some metal.
no-one noticed it..
(http://www.busafied.com/boostafied/sump.jpg)
(http://www.busafied.com/boostafied/sump2.jpg)
(http://www.busafied.com/boostafied/sump4.jpg)
Don't forget man if you DO NOT use the Vent off the "T" like it was setup you risk sucking the turbo bearings dry!
See the T below the motor, the line w/o a fitting came up and over the motor on the left side.
I marked the line fitings as I had them installed in these pics & the pump worked fine.
If you HAVE ANY questions hit me up in PM's-
The Return went back here temporarily, you could return it to the pan or same place, just route it cleaner.
(http://www.busafied.com/boostafied/sumpdone.jpg)
(http://www.busafied.com/boostafied/sumpdone2.jpg)
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ok, so fabbed up a bracket and put the pump on, and tilted it at an angle. the angle helps it clear around the underbelly and will allow for an easier fitment of the right fairing as well. i will still need to use some washers on the wing, but only like a 1/4in or so, so not bad!! the rest of the photos are showing the feed lines to the pump, and all is left on the feed side now is to undo the RCC return line and hook up its AN fitting onto the one i have.... look at how PERFECT they line up, and TOTALLY by coincidence too!!! the pump had to be mounted where it was, and the lines were made to length already, and it all worked at JUST right! but yeah, gonna drain oil and do that as soon as i get the return line figured out.
the return location i had pointed out is a 16mm x 1.5mm thread. it is a flat bushing type seal (has copper "gasket" at end of bolt, crush seal kinda thing). since i cannot make it clear the fairings using conventional methods (AN adaptors, i tried the AN fitting in the hole and THEN a 90deg on that, but hit fairing WAY too much). so my only real option IF i keep this as my return is i will have to make a custom banjo bolt.... other alternatives being sought out now....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo135.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo136.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo137.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo138.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo139.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo140.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo141.jpg)
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good/bad news!! i have foud that i have a boost leak.... the up-pipe has a rather large leak in it, a hole developed while touched the header after things had shifted and settled in on the bike. the hole was obviously a burn type hole, large enought o put a finger through. a piece broke off, but it broke off when i poked my finger though it, NOT while it was on the bike!! good news is i found a boost leak, bad news is now i need to fix it!! :lol:
my finger is pointing to the part of the header the hose was touching. my best guess thus far to really fix the problem is to make a new J-pipe from the turbo the has a bend in it, then use a coupler from there. that will ensure the best spacing from what i can tell thus far.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo142.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo143.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo144.jpg)
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time to fix the boost leak!! so i got a sleeve to fit inside the coupler, i trimmed out the excess, and then hose clamped both ends of the pipe to ensure no boost got by. isnt the ideal fix for longevity, but i want to race tomorrow!! so it will be fine for a day or two....
(http://i80.photobucket.com/albums/j196/stupid0995/turbo146.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo147.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo148.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo149.jpg)
and i dont have a photo of the sleeve (i cut it down to by the way) inside the tube, but you get the idea.
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and teh scavenge pump setup is done and runs!!! yehaw! so yeah, onto business... the 90deg fitting that goes to the RETURN of the motor was a bit tricky to find.... i had to take a 90deg part that was a 3/8 inner diameter fitting then take a die and re-thread it to 16mm x 1.5mm. then just put on a bit of tefon tape, and thread in. BUT you have to take off the starter gear cover thing to put it in!!! if you look at the return hole i put it too, the bard on the fitting will hit the cover when tightening it on, so you have to take it off. anf yeah, when you do, dont forget the tilt the cover BACK because a gear is actually INSIDE of the cover! and i tiny washer spacer, dont loose these!!
(http://i80.photobucket.com/albums/j196/stupid0995/turbo155.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo156.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo157.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo158.jpg)
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and, one more thing to looi forward to!! the swingarm!! right now i am doing the no-box mod, then i will underbrace it and do 0-6 over (ideally). this is the beginning of the no-box mod, will post tomorrow on the cut all the way around the box, following the line i have drawn.
(http://i80.photobucket.com/albums/j196/stupid0995/turbo150.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo151.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo152.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo153.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/turbo154.jpg)
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SO, new update!! bad news though... from what it looks like, the tensioner failed, and i bent some valves... i was riding home from a friends house one night, and i heard a light ting-ing noise come from my motor. it sounded MUCH like another pump, like a fuel pump, scavenge pump, etc, yet different enough from the ones i have to notice the new noise. i was at like 0% throttle, so i pulled in the clutch to see what the rpms would do, the drop to 0 and made a clank clank noise in the motor. oh no....
i tried to start it once or twice, but again it sounded like a blender of bolts :evil: so i pulled over immediately, and luckily a friend (roommate) was following. he went back to another friends house and got a truck and 3 of us got it loaded in the back (tough!!). got it home and it sat for a week until..... (look at following posts)
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(http://i80.photobucket.com/albums/j196/stupid0995/enginebust001.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust002.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust003.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust004.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust005.jpg)
if you look closely at the last photo, you can see the exhaust valves are open as well.... the cam lobes are down for them, so that is supposed to be lke that. i am more saying this to highlight how bad the intake are...
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valve cover off
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust006.jpg)
and here is kinda the run down of the take apart.....
there are EIGHT bolts that hold the motor in. you have to take to kickstand off to reach one. radiator has to go, exhaust, intake, TB's, etc. unplug some connectors, most ALL are in the belly area (where pump is and breather). you can look around and see prtty much all of it pretty easily. here are one side of where the bolts are. opposite obviously on the other.'
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust007.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust008.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust009.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust010.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust011.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust012.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/enginebust013.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust014.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust015.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust016.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust017.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust018.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust019.jpg)
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dunno quite why that one set of retainers has the oil on it..... that is also the ONLY really damaged valves too. i think it is coincidence, but none the less i thought it may be worth mentioning... (from previous post last photo)
and the valves:
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust020.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust021.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust022.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust023.jpg)
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overall the head damage is rather minimal.... well, thus far. there is a lot of corrosion on the exhaust valves :? not sure why either. maybe it got really hot a few times, but it doesnt really look like detonation. hmm, guess it may be worth trying to replace all the valves then. pistons look in good shape, and NO scarring on the cylinder walls!! :thumb: good news too. thankfully the valves didnt break or anything, so there was no serious damages to bring the motor down terribly.
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust024.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust025.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust026.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust027.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust028.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/enginebust029.jpg)
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ah yes, and one more thing... when i first took the valve cover off, i turned the crank with a wrech. it tighetened, then would skip over the teeth on the intake side (bent valve side). so my guess is that the motor skipped a tooth, started a ting-ing noise (heard it for 5 sec), then skipped another and whammo!
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damn man atleast you know where you are now at this point, well for the most part.
GL,
Ron
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sorry for the long delay.... was gone for 5 weeks....
update: i am waiting for it to warm up a tad to clean my head and begin re-assembly. i bought a new head (new to me at least...), and i even got a lightly damaged mcxpress intercooler!! hopefully can get the bike up and going, then someday get the intercooler fitted.
also got a new head gasket in. just need to figure out how to get the recall tensioner in... (for free that is..)
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and here we go again!!
so, this is what the valve looks like out of the old head...
(http://i80.photobucket.com/albums/j196/stupid0995/DSC03530.jpg)
i got the timing back together (at least i hope...), and rotated it a few times and there is no interference!!! so thats a plus. one of my friends (local guy) had a spare APE cam chain tensioner, so i am going to use it to get the bike together, then take it like that to the dealer after i have confirmed that it runs. here is what the engine looks like now (almost ready to go back INTO the bike!!)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC03531.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC03532.jpg)
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IT RUNS AGAIN!!!!
i rode it around a LOT the past 2 days or so, runs great!!!! kinda odd things though.... 1: new battery died, so i must have a short. 2: boost is WAY out of control!! i had like 4-5 psi or so before, now like 12-14!! :shock: so yeah, as soon as i realized that i let of the throttle a LOT!! but hey, at least i know that i must have a good tune :lol:
but seriously, that was kinda spooky, especially without anything to cool the air like an intercooler. so i will have to investigate. it would have to be something to do with the W/G obviously, so time to poke around again.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC03540.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC03539.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC03538.jpg)
and i did put the fairings on later after these photos, so she is all back together!!
started on the FIRST try too!
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It looks like you are over-boosting because you have a Boost Line on TOP of your Waste Gate...
(http://i80.photobucket.com/albums/j196/stupid0995/DSC03540.jpg)
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It looks like you are over-boosting because you have a Boost Line on TOP of your Waste Gate...
WOW, duh to me! haha, totally forgot about that one going on the bottom :lol: well, at least that is the easiest thing ever to fix!! good call and thanks for the looking!!! :thumb:
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good to hear shes running again :thumb:
Once I got mine rebuilt I had the same issue, took it for a spin hit 12 psi :bah:
Mine was leaking at the barbed fitting on my gate (it was split), just enough to act as a bleed off valve.
I found it when I decided to blow through the line from the turbo comp housing just to see if it had a leak,
and what do ya know- heard air coming out the other side of the bike.
Initially, I thought I tore my diaphragm in the gate :P
Keep up the good work-
Ron
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Are you using that silicone gasket maker shit instead of stock or Cometic? If so.......be careful......that gasket maker shit will fall off and get into your pump and screw it up! My $.02.
Jason
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Takes talent to do all that work alone...impressive, hope that all goes well this go-round.
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Congrats!
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So new update!!! I am getting a +6 arm (hopefully here this week..)!!
So I needed to do some undertail work. I bought a piece of galvanized steel from lowes, $11 w/tax. I made my patterns from old plastic folders that I had left over from college, as well as the cardboard pieces on the bottom of a notepad. I used some self tapping screws but pre-drilled them to ensure a good bite (sometimes the screw can wear out while tapping and break the head off, BAD!).
Here are the pics!
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05732.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05733.jpg)
This is what I cut off
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05734.jpg)
Front part of the new undertail box.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05735.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05736.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05737.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05738.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05739.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC05740.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05741.jpg)
This is the basic steps to doing the self tapping screws, or at least how I like to do it :)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05742.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05743.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05744.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05745.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05746.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05747.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05748.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05749.jpg)
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(http://i80.photobucket.com/albums/j196/stupid0995/DSC05750.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05751.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05753.jpg)
Full size magazine/catalog!!!
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05754.jpg)
This is the pattern I made for the rear section of the undertail, look down further and it will make sense.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05755.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05756.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05757.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05758.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05759.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05760.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05761.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05762.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05763.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05764.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05765.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05766.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05768.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05769.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05770-1.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05772-1.jpg)
It fits a full size drill, with battery, AND a large impact wrench!!! Still room to spare lol.
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05773-1.jpg)
And a gallon of milk fits too!!!
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05776-1.jpg)
(http://i80.photobucket.com/albums/j196/stupid0995/DSC05775-1.jpg)
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lookin good! im tearing mine apart as well and lowering compression, studding, etc, the usual. If you could pm your number or reply with it i need to give you a call about those extra valves you have.
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Hey give us an update!
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Hey give us an update!
:thumb:
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Hey man hows it coming along?