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Post by colinworth79 on Dec 24, 2013 21:50:58 GMT
The turbo looks like a TD04 same as what im running on my 1216 bandit . Fitted to volvo T5 or later V70R . Have a look on the tin plate on the compressor housing hopefully should say 15G or 16t (later ones) There was various TD04 turbos fitted to different things but the 15G or 16t best ones for 1216 oilcooled engine . Looks like some one has cut one of the mounting points off where the stock dump valve is fitted but is not a big problem as you want to blank that off with a flat plate .
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Dec 25, 2013 16:28:39 GMT
Looking great, love the engine finish, can I ask who aqua blasted your cases? AJ Vapour blasting in Hull did the casings, nice job as well.
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Dec 25, 2013 16:34:43 GMT
The turbo looks like a TD04 same as what im running on my 1216 bandit . Fitted to volvo T5 or later V70R . Have a look on the tin plate on the compressor housing hopefully should say 15G or 16t (later ones) There was various TD04 turbos fitted to different things but the 15G or 16t best ones for 1216 oilcooled engine . Looks like some one has cut one of the mounting points off where the stock dump valve is fitted but is not a big problem as you want to blank that off with a flat plate . Ohh, that's good news then! I'll get out into the garage tomorrow and do some better pics of the turbo. There's no markings what-so-ever except for the VOLVO casting in the cold side. Great info about blanking the plate off, I was a bit worried as one of the bolt holes was trimmed... While the madness of Xmas is all around, I'm submersed in my lappy draggging and indexing every bit of info available Just looking at intercoolers at the moment as well, but someone went and put the front wheel and steering lock in the way for where I'd like to mount it... Thinking of running a bandit cooler and put the Earls one at the front, but want to run a head cooler and there aint enough room lol
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Dec 26, 2013 11:31:42 GMT
More photo's of the turbo. It's completely unmarked, a long number cast into the hotside of 6-189-13302: This is the shape of the exhaust inlet: And this is all there is on the cold side: So, on with other things. Other than making my list for all the little bits I need from Newark in January, I got on with checking the deck height of the busa pistons and rods on the 1127. They stick up quite a bit... So what I did was put my dial gauge on the centre of the piston (as they rock quite a bit), laid a straight-edge across the top of the barrels and raised the piston to it. I then took a measurement. I know its not quite on zero but it's not that important. I then turned the motor to proper TDC, back-and-forward a couple of times and took the second measurement of 1.7mm. So, all I need to know now is the deck height of a standard 1127 piston & rod then I can do some calcs. And fortunately I have them: 0.80. It wasn't too scientific as I was using a vernier caliper but it gives me an idea of where I am. On top of that there's the base gasket thickness to add but also the fact I had 0.0762 mil skimmed off the head. Need to spend a bit of time checking out what thickness gaskets are available and also how may cc's I've ended up with in the pots. On a separate note, where's the best to go for the oil feed line? Thanks for looking Simon
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Post by colinworth79 on Dec 26, 2013 20:58:29 GMT
When you say oil feed line are you refuring to the oil feed for the turbo bearing ? If so normally taken off just underneath the ignition pick up cover . The oil feed line -03 and needs to have a restrictor fitted to stop over oiling the turbo . Going back to your turbo you have, only way to find out which one is to take off the compress housing and measure the compressor wheel .
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Post by fula28 on Dec 26, 2013 22:45:08 GMT
Nice job so far , as Colin has said its td04- But as I see your exhaust flange is angled it's looking like a -15 or such as most td04-16t up wards are straight flanged this volvo t5 v70 type there 250 bhp out the box but on a bike . Oil feed must be as per Colin's pointers -3 restricted, and -8+ for drain to sump or scavenge pump ,I used old emulsion tubes cut down and fitted with mikuni jet 1.00mm to restrict in the banjo fitting bolts. Cheap modd, only run best scavenge pumps with metal gears and constant use!!! Type, lots put there and there shite, mocal or such are best, or crank driven , scavenge works well, otherwise smokey all the time and oily compressor time been there done that. you can get upto 350 with right internals , inter cooler ect , I run td04-16t which is from t5r and 7 psi makes 209bhp on std b12 top end No tuning, 34mm carbs , I'm building a new fresh motor in summer with busa slugs like you have also, I plan to run more boost so I too need a cooler and, 1216 multiple layer gasket, etc. best advice is build it right build it once at get it jetted right too, guess you having a lockup clutch as std one won't stand more than 170-180bhp, (just a thought), Keep pics coming as it's looking great so far, Nice one fuller.
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Dec 28, 2013 19:21:15 GMT
Thanks guys for the input, I've got a bit of reading to do on thread sizes and not quite sure how you put the jet into the line... As I haven't got any circlip pliers to get the circlip off and split the cold side I had to measure the mouth of the inlet. It measures 45mm and the impeller looks the same size as that. Is that any us to you regarding the size of turbo? On the scavenge side I have one of these pumps, sold by RB racing, although the gears look bronze and not metal to me.. For the fuel pump I'm using this Bosch one: And I got a SYTEC 30 micron filter and have ordered a Malpassi twin-outlet vacuum controlled regulator. Going to mount some of the hardware on this plate, just in front of the battery. My idea is the scavenged oil will come up from the turbo, over the back of the swinging arm, into the scavenge pump and either drop in where the plug is on top of the alternator or a custom inlet on the clutch casing. I specifically don't want to drop the oil into the sump, I'd have thought it would have been both very hot and very aireated so I'd prefer it to mix in with the clutch oil and heat sink through the engine before entering the sump. I read on the RB Racing site it needs to be mounted upright with the gears at the bottom so the bracket is the only viable place for it. So, at this moment in time I'm waiting for bits and getting my never-ending list ready for Newark next weekend. Thanks for looking Simon
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Post by colinworth79 on Dec 28, 2013 23:20:49 GMT
Simon i fitted a 100 brass carb jet into the end of the banjo bolt ( pressed in ) at the turbo to restrict the oil flow . Have the same RB racing scavenge pump as you , mine is mounted just behind the sump under the suspension rocker . Not sure if it will work well enough mounted higher than the turbo . Oil return back into the clutch cover above oil level . You will need a one way valve after the scavenge pump to stop oil draining back and filling up the turbo when left standing . I have a project thread ( GIA turbo bandit ) on here if you want some pics to look at or can send some over to you if you need help with anything .
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Dec 29, 2013 8:43:15 GMT
Wow Colin, HOW THE HELL DID I MISS YOUR THREAD! smileystick That is a beautiful bike, and amazing engineering. Excellent information, thanks for making the restrictor more obvious! I'll remount the scavenge like you have. RB did put in their site the pump has to be mounted vertically or there's a possibility of seal damage - although is it just me reading into a country swamped in a litigation-frenzy too deeply... On your input side, what's the alloy block (circled), is it just a reducer or is that where you've put your one-way valve? Where's the best place for the alloy fittings, too much scope for error ordering the fittings online, think it needs the bike at the supplier for a proper measure-up. Simon
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Post by colinworth79 on Dec 29, 2013 21:33:24 GMT
Ok the bit you have circled on the photo is just an adaptor . Im running a -12 line from the turbo back to the pump . Ive tried to run the largest bore pipe possible to act as a resivoir when the bike is left standing . The one way valve is after the 90 bend . Ive got my fittings from 'torques' , look on ebay ,after looking through my deemon tweeks motorsport catalouge to decide on sizes/ fitting type .
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Post by CHR15 on Dec 29, 2013 21:34:23 GMT
torques for fittings and hose. (on ebay)
i didn't run a restrictor on my td04. never had any problems with just a -3 line.
i find drawing a little line diagram of how everything will be plumbed and then annotating it with the fittings needed helps avoid ordering the wrong things.
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Post by colinworth79 on Dec 29, 2013 21:37:20 GMT
Forgot to add , the pump has been mounted that way since 2009ish doing about 500/600 miles a year and has been no problem .
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Dec 29, 2013 21:52:20 GMT
aww guy's your spoiling me now I've been slavering over Torques ebay page, never thought of spec'ing the DT catalogue though, cheers for that. I'd thought an12 for the return for the same reason, good to know the scavenge has lasted the distance. I'll get onto the fittings tomorrow, just trying too hard to knock stuff out of the park in the short time I've got before back to work So much stuff is going through my head at the moment it's unreal, keep waking myself up with new ideas. Luckily not back at work until Jan 6th lol I'm pouring over flow diagrams for the plenum entry at the mo, hoping to get all the alloy I need at Newark, then off to Mr Silicone for the rubber bits and inlet tubes, just trying to think 2 steps in front as this needs to be done and run before Straightliners in March. Once again, thanks for all the valuable info guys, if the bike doesn't skint me, the beers owed will... Simon
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Dec 31, 2013 15:52:49 GMT
So, New Years eve is upon us, and was woken by 3 mr postmen bringing individual parts of a big (read expensive) delivery: So now I have a set of Dyna coils, Taylor leads, Cometic head gasket, APE manual cam chain adjuster, correct boost controlled pressure regulator, and after a longish talk to Debben, a 2mm base spacer. Unfortunately, my lock-up isn't here, neither are my APE cylinder bolts, which is going to hold me up loads as I want to get the deck height set properly I'll have to call after NYday and see if I can cancel them and order from somewhere else. In the meantime, I decided to put it together sans studs just to see where things are. So, what we have is a new base gasket, 2mm spacer and old base gasket (forgot to order an extra one....) It's going to be a right laugh getting the barrel down on the pistons come proper build time as there's a lot of stuff getting in the way popping it down with one piston, no rings. I think it might be pistons and rings in barrel first then just struggle getting the circlips in... Back to the task in hand. First of all I found the centre of the piston (more accurate as it doesn't rock like it does at the ends) and set the DTI to zero after finding TDC. Then, I lifted the tip and moved the DTI in an arc so it just touched the sleeve. It only moved about 4mm (or a couple of degrees) and was the only way I could think of doing it keeping my original datum line So we're looking at 1.12mm drop down the bore, which, obviously will change when the barrels are torqued down but I'm certianly more happy now its closer to the 0.80mm (less base gasket) I had when I measured it before. As I can't do anything more on that side I decided to clean up the clutch steels and check the fibres. Hmm, fibres knackered. Now they'll come out at about £100 with the OSS discount but that's still double the EBC price, so I put a post up on Facebloke and the overwhelming consensus was OEM. Ordered from Robinsons. Remember the OSSD code at checkout gets us 10% off... Been thinking about my fuel return, and reading up I've found it needs to be big, unrestricted and fitted somewhere in the tank. I've a spare 1100 tank so the logical thing was to remove the fuel sender, run a big drill down it, clean it all out, braize a 8mm tube into the brass fitting and fill the outside hole with araldite. Here it is drying (hence why it's upside down...) This does mean I can't run the original bodywork as the 750 tank doesn't have the fitting. Well, I assume it doesn't - I've not actually checked as its balancing on top of the units just waiting to come crashing down Well, no more for today, got to start getting ready for the celebrations. Mine won't start until this turbo build fires into life - then it will be a happy new year. Thanks for looking, Simon
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 3, 2014 15:53:15 GMT
Just sat here waiting for Newark show so I can get the rest of the alloy stock and get some bits fab'd and off to my welder to be stuck together. In the mean time it's been a slow delivery day from postie. My OEM clutch plates and 2nd base gasket came courtesy of Robinsons, and this take-a-gamble moment I took a punt on just before Xmas: Originally badged as ZX10 04 - 05 extenders, the more I looked at the picture the more they looked like they'd fit the slinger swinger. I made a silly offer, he made a slightly more sensible counter-offer which I accepted and they arrived today So, putting them up against the (albeit 750) arm, they're close enough to be worth doing! (not wonky, just difficult to photo while balancing everything) Bit that goes through the adjuster is slightly longer but the same height, and it looks like there's plenty enough meat on the rear of the slinger adjuster to make that fit, also they'll fit nicely at the front with a rounding of the front edge to match the curve of the GSXR Just need to remove the gixxer wheel adjuster and the fit at the rear is super snug! Height-wise they're about spot on as well. I would say they'd go together without welding (as designed) but I'll wait for the decision from my welder/fabricator. Don't really want to have the swinger re-powder coated if possible as I had to spend on two new bearings trying to get the old ones out Best bit as well is even the spindle is the same size Should sort the wheelie problem out Thanks for looking, Simon
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