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Author Topic: Turbo ZX-12R  (Read 12340 times)

Offline KZScott

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Turbo ZX-12R
« on: February 09, 2012, 09:01:21 PM »
this is cut n paste from another site so i hope it flows ok.....

my 12 has a Master Power T3/T4 T60-1 turbo, home fabbed header, WA cooler built into the frame, AEM progressive water meth injection modified with Devils own nozzels plumbed into the TBs using some of my old nitrous stuff. It runs on 91 octane pump gas. MS2 ECU with upgraded firmware. 255lph Walbro external fp, AEM 1:1 regulator, ID 725cc injectors. I did all the work myself except for the tig. its been a real learning curve!
motor is stock bore and stroke, JE turbo pistons, and a ported head/modified combustion chambers by me. final CR ended up being 8.7:1. two stock intake cams, APE adjustable sprockets. APE studs, stock 01 crank and rods, 02 cases with oiling mods to restrict oil to trans(by me), R&D trans w/billet Robinson 1-4 output gears. Muzzy clutch basket, MTC lockup. I had 6 hd Muzzy springs in it and took my voodoo hold back springs off of the lock up to i had 4 arms applying pressure to make sure it didnt drive thru the clutch on the dyno(may have been over kill). Muzzy dry sump oiling system, filter relocator ect.

I had to build an attachment to be able to use the dyno. (the real one from Mustang is about 3k$$) this was the first time it had ever been put into bike mode, and i believe it had a calibration error. the operator is going to look into it for future bike use. i was mainly worried about getting a safe tune up and wasnt set on hp numbers, but for those who care, i believe it was reading exactly double what it was really making. at 25 psi it was showing 834 hp, so half would be 417. add roughly 15% to convert Mustang to dynojet hp and its about 479 at the wheel. it may have more in it as it was in the low 11:1 range AFR wise.

this build has happened over various locations, and i cant thank everyone enough thats helped privately on my secret project. you know who you are guys, DM, JG, WH, DS, CH, ppl on other forums and local.
not trying to rip anyone off, but Ive sort of nicknamed my build the ultra ghetto 12. based on what it reminds me of. Motorheads ghetto turbo kits and Richards RCC ultra turbo kits. this has definately been a budget build which is why its taken over a yr. I havent allways had the best equipment or places to work, but I make due with what I have, and then every now and then I splurge a little if my CCs are getting close to paid off :D

pics

header flange/turbo flange 1/2 mild steel.



hanging the turbo off of dads bike (making a jig). this was when he swapped to my old Brocks system and timing was perfect, my bike was in my apt bedroom at the time(no joke) and i needed to be able to weld the jig together. not possible in my bedroom!


making the header 1.5in schedual 10 304SS pipe
this design is one i would change a little if copying, i cant get 1 of the header bolts in, but so far its been ok. i think because the flange is so thick.


I would cut and fit pieces, using a 4.5 in grinder and a dremmel, then run and get stuff tacked by my tig guy.






my work station, making the best of what i had :)


the rest of the exh was easier. 16 gauge 304 and a tiwinder meg. it was important to me to have good ground clearance both going down the track and making the turn to the return lane. I tucked it in tight as best i could, then fitted the gate. got it for a steal on SH.org. its, big, its rusty, but it works and has been over 220 at bonneville.







charge pipe. 2 1/4 tubing



frame mods and cooler.
this next part took a lot of fab work, and if doing it again, i would make a few small changes. used a WA cooler from frozenboost.com. core size is similar to whats used in the older ultra kits. i basically used my blown up motor as a jig to hold the frame from twisting when it was cut up/ welded on. went thru several design ideas during the build process

this part felt just like i was cutting off my own hand(minus the obvious lack of physical pain)


yes Muzzy stacks



1/4 plate




the cover has 2 grooves dremmel'd into it, and i sealed it with permatex ultra black(think engine cases). its no oring seal, but it working.  after yrs of cursing the tiny inspection covers i really wanted a big one. this was the time to get some room to work when installing velocity stacks.
scotts damper mount, boost proof and never have to stick hands up in the frame for the nuts ever again. 1/2 in square stock drilled, tapped, then the ends of the holes capped with weld, flipped over and welded in..







water meth, direct port. only real way i could see getting even distribution post cooler


the pump and tank are located where the top half of the gas tank used to be, i need to get current pics

this was a tight fit


filter and return. i just made an adapter plate and used the oem tank gasket. pump is located in the battery box


cut down my stock rad to clear the turbo. electric water pump

i used part of another stock rad as the heat exchanger for the WA cooler. 2 seperate cooling systems. the second water pump is beside my fuel pump



turbo oil feed. i did a coil to hopefully account for thermal expansion. i didnt think a hard line would work in a short run, but the coil is flexable. the fitting on the filter relocator was soldered full, then drilled out to .063. this is something i want to check out now that its been on the dyno. and had some heat. its 1/8ss line, same as i use in nitrous systems and my water meth setup.


gauges. so far the MS2 can run the tach, but the speedo isnt working. i also have the water temp working. i wasnt sure if i would have been able to get it going with my computer programming "skillz" so i got the autometer gauge just incase


missing tooth wheel( cut one tooth off) so the ms2 can read crank pos without cam input. easiest way to get things running. batch fire the injectors and wasted spark

I plan on upgrading to full sequential with cam input at a later date.

oiling mods





pistons in the hole just a little. 2 base gaskets

from checking cr


modified chambers to lower cr. std size valves, std seats, stock IN, SS EX
running Carpenter 65lb springs, and APE Ti retainers





heres a printout i was given, first clean pull on gate pressure (6lb spring turned out to be 5.3) and the pull at 25.3psi
keep in mind what i said earlier about the correction factor or calibration error...


at 27psi it cracked the stock block....


we had it on the dyno on a monday, i took it apart on tues night after work and found that ^^^^


i was able to get it going with a worn out stock block that week and got to the track sat afternoon. last race of the yr!! I hadnt raced my bike since i blew up my big bore stroker motor. middle of 2010.
i ran it on low boost that wknd and it felt really strong. its quite a learning curve to get the launch control figured out on the ecu, build boost on the line ect ect. i set the clutch pretty stiff initially and it bogged pretty hard, i upped the power in baby steps and my best was a 1.53 60. any more power and it was blowing the tire off and going 45degrees sideways, into the other groove and allmost out before i got it under control. the pass with the 1.53 was an 8.86 @168.9mph. power was smooth and controlled after the launch. i really like the gear based stages of boost.




a friend got a few pics








01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline KZScott

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Re: Turbo ZX-12R
« Reply #1 on: February 09, 2012, 09:03:51 PM »
I have a few parts to upgrade it this winter. I wont be cracking this block under boost :D

84mm billet block, semi wet/dry. machined for SS O rings. this is what Gadsons and Rays shootout bikes used, the promod Schnitz drove ect. all made over 500hp



Dave Turner: It still runs the coolant but now the block is way stronger. We tried dry block and full wet block and this by far was best for equal heat transfer. Its the same cylinder we used on our street strip bikes we have built in the past. Just make sure you bleed the air out of the system good.






OEM rod, bushed by Muzzys for their spec custom small pin turbo pistons.



84mm turbo piston. very rugged design, a little heavy, but it needs to be extra strong

somebody did a little work to these. pre prepped. NICE! Thanks Muzzys!



when you machine a blank intended to be 82mm at 84mm, you get a very thick, very strong piston. a little heavier than normal, but required when making over 500 rear wheel HP with a 1.2l

at first glance, these look like normal pins, but look closer (the flash really helped) and you will see that the ID gets smaller towards the center. its very very thick where the most stress is




and Im upgrading my 60-1 to this T61





pic of the water meth tank/pump. nothing fancy, just used what was kicking around



ill be using the bushed stock rods in the new build. Muzzys told me that the rods and pistons they sent were good for 32 pounds of boost. I dont plan on running more than 30.


Making some progress. heres the big boy hanging/sitting where its going to be living this yr



while my first header worked pretty well, Im sure version 2.0 is going to work much better, I learned a lot building my first one.





made this bolt on jig so if I ever need to copy this I can easily. I also marked out an extra header flange



spotting everything with 3/32 308 rods. old school Arc welder. it will be finished by a pro with a Tig





the dents are for a little more room around the bolts in the turbo flange. its tight














I think version 2.0 is going to work a little better than the original :)


Im very happy with it. its my second header (ever). time to start the gate piping and exh. had a pro do a little tig today (and I need to get some bolts....)









just barely enough room for the K&N air filter. the rubber touches the Muzzy oil filter relocator


able to fit a full rad with it shimmed out 3/4 in. could have made the turbo flange a little tighter to the block for less shimming but wanted to be sure i would have enough room for dual piping for the gate. next time...
i can get my finger between the fender and rad with it lowered this far. going to trim the fender for more room


1/8-3/16 clearance. going to wrap the header to minimize heat transfer


3 in exhaust tapered down to 2 3/8 to fit the TiWinder meg. going to redo the taper to make it longer/more gradual.


redid the tapered section. made a longer cone and this time asymmetrical to maximize ground clearance









i had originally planned on coming off the header, but this is what i finally ended up going with. several designs later....



sch 10 pipe for the main tube to support the big gate and 16 gauge for the other side of the divided housing.



going to do a little extra welding in here to smooth out the transition in the corner


my ugly tack on the turbo will be ground off after its tacked by a tig, then tigged all the way around with the proper filler. i dont have 309




shining a light in the waste gate flange






my helper










should only need about 45 degrees and part of the leg on the 180 degree 1 5/8 U bend i got. ill make this after i get a 3 in v band clamp this week. something tells me duct tape wont do lol


charge piping mock up


the compressor housing is very close to the Muzzy oil filter relocator, but has plenty of room, it looks rather tight in these pics




the K&N air filter does touch, but its not crushed or deformed any from the contact. a little tighter than i wanted, but its liveable



air filter sticks out a little more with the bigger turbo in a slightly different place than the last one. not quite as stealthy, but may pull more cooler air this way from outside the plastics


exh tucks in nicely, I hate a SW that hits when you barely lean the bike over


















weighs 38 pounds. should help hold the front end down :lol:



charge piping ready for final welding






getting VERY close to testing this





size reference. the K&N filter Im using on the anti surge housing is the RU2510 http://www.knfilters.com/search/product.aspx?Prod=RU-2510



forks sitting at full extension




full compression


about 7/16 to the tire. if it rubs i know that i can get at least another 1/8 from a tire swap on a 17in rim. (currently running a 120/60 Pirelli)



normal looking scoop. bone stock....


forks fully compressed and dropped 1in in the triples. looks like its hitting.....


....not hitting!






still room in the back, no need for a short neck mod just yet...


1 1/4 fork travel, this is where it will be strapped down. i need to remake mine.
01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline jgennaro

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Re: Turbo ZX-12R
« Reply #2 on: February 09, 2012, 09:35:12 PM »
Holy shit........nice work! :tu:

Speed, it seems to me, provides the one genuinely modern pleasure.

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Re: Turbo ZX-12R
« Reply #3 on: February 09, 2012, 10:20:17 PM »
 :tu:   Great work Scott
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Offline Deespeed99

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Re: Turbo ZX-12R
« Reply #4 on: February 11, 2012, 12:38:04 AM »
One of the most unique and well built DIY projects I've seen! Awesome work man!  :tu: :tu:

Offline KZScott

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Re: Turbo ZX-12R
« Reply #5 on: February 11, 2012, 06:34:30 PM »
thank you! :mrgreen:
01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline Penianator

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Re: Turbo ZX-12R
« Reply #6 on: February 11, 2012, 09:25:47 PM »
great looking build man! Welds look like they were properly done and purged.

Offline murderedout07

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Re: Turbo ZX-12R
« Reply #7 on: February 12, 2012, 12:01:37 AM »
Bad. Fucking. Ass!!!

TURBOLAG: The split second the other guy thinks hes winning.

Offline Chuck A

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Re: Turbo ZX-12R
« Reply #8 on: February 12, 2012, 12:09:30 AM »
very nice, indeed

Offline turbojonn

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Re: Turbo ZX-12R
« Reply #9 on: February 12, 2012, 02:59:31 AM »
Datum! I loved this build write up. You are definitely not the average wrencher. Wow! Do you think your front wheel.will still clear under heavy breaking?
RCC turbos rock!!! Rcc- Ultra plenum, case saver, Carillo- rods, Wossner pistons, APE- springs/tool steel shift shafts, Ferrara valves, ARP studs, lightened and balanced crank, Boostbysmith ecu editor, AMS 1000 with CO2, Joemoto motor. Mac arm 0-6 over, BST carbon fiber rims. Someday I'm goin' fast!

Offline KZScott

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Re: Turbo ZX-12R
« Reply #10 on: February 12, 2012, 10:05:55 PM »
thank you guys, its been a lot of work, but the learning curve has been great, and is still going strong. Its all worth it.
not sure on the front wheel. i think it will be ok as i added a second brace to the rad where it only has 1 side braced stock. should help with flex. ill be keeping an eye on it and if i need to go with a lower profile tire i will.



Need to pick up a prebent hose


oil drain needs to go see the tigger. hand made from 3/16 plate and a hose end from a junk hydraulic line.




Drill and tap here
01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline proutyc

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Re: Turbo ZX-12R
« Reply #11 on: February 14, 2012, 03:22:09 AM »
Awesome build.... :thumb:

Offline Mike-Nightrider

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Re: Turbo ZX-12R
« Reply #12 on: February 14, 2012, 04:01:03 AM »
Great work Scott :tu:  Hats off  :bwdwn:
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1/8: 5.101s..........1/4: 7.801s
227.7mph Woodbridge/GB 2013

Offline KZScott

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Re: Turbo ZX-12R
« Reply #13 on: March 09, 2012, 10:41:33 AM »
01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline gsx-rboy750

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Re: Turbo ZX-12R
« Reply #14 on: March 10, 2012, 08:24:36 AM »
Ya really nice work and fabrication. I like the way you cut the pipe with a clamp and 2 other clamps.
I had to do the same thing to my radiator and was going to do a 2.0 header also. I like seeing people doing the work themselves and then reengineering to improve.

Offline KZScott

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Re: Turbo ZX-12R
« Reply #15 on: March 10, 2012, 06:13:30 PM »
thank you, I built the whole thing with basic had tools. I dont know how to run fancy stuff any way :hys:

got some heat in it :)


I have ideas for a 3.0 now.... to make more equal length. but ill run 2.0 this yr
01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline Chuck A

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Re: Turbo ZX-12R
« Reply #16 on: March 10, 2012, 10:18:46 PM »
any audio?

Offline KZScott

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Re: Turbo ZX-12R
« Reply #17 on: March 10, 2012, 10:23:51 PM »
yes the video has audio on my fb page
01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline Lumpasaurus

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Re: Turbo ZX-12R
« Reply #18 on: March 17, 2012, 11:26:43 AM »
Super bad ass.  Way to think out of the box.   Very well thought out and done.

Offline big a

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Re: Turbo ZX-12R
« Reply #19 on: March 17, 2012, 12:03:26 PM »
great work :tu:

Offline KZScott

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Re: Turbo ZX-12R
« Reply #20 on: April 11, 2012, 08:26:55 AM »
Thanks guys. due for an update. I was sponsored a Ballistic Evo2 battery from Warp 12 Racing, and put it where i had the ecu last yr. I got rid of the 2 oem batteries i had up front and returned the oem headlights back to the bike. racing at night sucks without them!! I also now have 10 more cca. 200 each for stock, 410 for the new light weight :D






(brackets were tig welded, the tek screws were removed)

pulled the JE pistons out and found some cracks  :sick:







Muzzy spec MTC




started a new water meth tank. frees up a place for the ecu, and wont require any body work removal for filling or checking level  :)



01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline Lumpasaurus

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Turbo ZX-12R
« Reply #21 on: April 11, 2012, 09:29:10 AM »
Nice ! 


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Offline KZScott

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Re: Turbo ZX-12R
« Reply #22 on: May 19, 2012, 12:44:11 AM »
good news and bad news from the dyno. bad is im out of injector at the current fuel pressure. good is i have more hp this yr at 20 psi than i did last yr at 25!! :D instead of starting all over again tuning with more fuel pressure i called it a day and will try to race this wknd. Im still learning the tuning software, so i didnt want to run out of time starting from gate pressure again.  I anticipate getting to the track mid afternoon tmrw, and will start retuning next week. i had base FP at 43 psi on my AEM 1:1 boost referenced reg, have a Walbro gsl392 pump, and ID725s. I logged a max DC of 96% on the pull and it was at 12.3:1 AFR, which needs a little more fuel IMO. I may try as high as 15 psi on the track before retuning

heres a dyno chart from last yrs setup showing 5.3 psi and 25.3 psi. keep in mind the calibration is not setup properly, and we think that its reading double or somewhere around there.


and heres a screen shot of the best run of today at 20 psi (look for the corrected number)
01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos

Offline gsx-rboy750

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Re: Turbo ZX-12R
« Reply #23 on: May 19, 2012, 07:16:36 AM »
Some nice heavy numbe

Offline KZScott

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Re: Turbo ZX-12R
« Reply #24 on: August 29, 2012, 09:25:58 AM »
been awhile since i updated this, had an issue with a clutch hold back spring getting into the oil pump... toasted the motor, back together with new cases, crank, rods, 1000 cc injectors, multi stage clutch. finaly having some fun, and tuning on the track now for the bigger injectors, it hasnt gone back to the dyno



having some fun with the T61 setup, so far got a best of a 1.34 60 ft, but the back half of the run was garbage. best et to date is an 8.68 @163 with a 1.44 60ft my previous best launch on a street tire was a 1.40 on my 1380, so I was happy to get in the 1.3s 3 times this past wknd. had limited runs do to a lot of issues popping up, but found solutions for all.






























01 ZX-12R 8.84 @ 156.3 on dot tires, pump gas, NO power adders.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot... turbo 8.32 @ 173
00 ZX-12R  1: 222.046 1.5: 226.390 Loring AFB Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1  1.5: 266.5 Loring AFB Worlds fastest ZX-12R
Fabricator/Engine builder @ RCC Turbos