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Post by katana on Jan 19, 2014 22:39:10 GMT
out of interest katana, where did you get you ic core from? Its a Pace core from the States I think (I never bought it - just finished it with fab'd up tanks and pipes) - size is about 325w x 125 d x 60t
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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 25, 2014 20:24:21 GMT
Trying to keep a weekly diary of the build. Here's this week. finally got the head on and torqued down. Now (hopefully) the work can start Finally got the headers on properly for the first time. Had to bend the bottom oil cooler brackets out of the way as they fouled on the headers. The turbo was originally designed to fit the "J" model Just love the quality of the welding Took a measurement of the exhaust flange. I need two; one for the straight through pipe and one for a slienced pipe necessary to please the Straightliners noise tester. If anyone knows where I can buy them, please get in touch! Started cutting the ASH bends I bought. Turbo first: May put some stronger tape on it though, I've heard these make a lot of pressure and can blow away weak tape Nice and close fit: I decided to change the plenum to carb rubbers as I am using the 750L 38mm carbs and the stretch onto the carbs was a bit much. I had to buy 4 51/59 reducers and then cut 90% of them away Looks and fits a lot better now. It's a real tight fit getting the plenum in without the grief of fighting with the rubbers as well. Obviously, when the jetting's right it should never need changing but it's one more job done right 1st time. Look a lot better on: Time to start fettling the inlet onto the plenum: Not bad. I actually finished this one off and then at the last minute threw it in the bin and remade it as I didn't like the angle it was pointing down at. I originally did it so my leg cleared but decided to go more for aesthetics and keep it parallel. Time to measure and then cut the front 90degree hose: Tried doing it with a jubilee as a template and another 51mm tube inside but I found it easier cutting with an empty tube. First bend fitted. was really akward as the cold side of the turbo wanted to drop off all the time and the tape kept breaking. But as I haven't got access to an alloy welder I had a few things to mock up before taking everything over to Simon at SF Services to stick all the alloy bits together. Decided to get the lockup fitted, seemed to have too much distance with the long spacers and the small washers fitted so I put the small washers on the top of the lockup to keep the bolt length the same. Also got the turbo oil feed pipe done as well. Used the rear brake hose as it was the right length. There's a 1mm restrictor in the turbo housing so I thought just use an3 all the way down. While I was at it I decided to make new gaskets for the clutch and lockup plate. Took me back to my apprenticeship days lol! Reference pic for the breather. Also where the scavenge feed is going to pop back into the motor. The casing had damage here (which I didn't spot before) so I'll just have the an10 fitting welded in. Two birds with one stone. Gone back to stock ignition for the time being, I contacted the guy I bought it off and he couldn't find the proper sensor. I'm saving for a new Dyna system now. So, everything was taken over to Beverley to be welded, also new spacers for the rear wheel, lots of tags/pitot tubes and general alloy welding magic should be occurring over the next few days ready for pickup next Friday, which gives me time to get the carbs stripped, o-rings renewed and float heights set. Going to go with the settings in the carbs for the time being, which is standard 750L but 144 main jets. Should be a good place to start. Need to start thinking about the wiring as well, but need to get a few more jobs finished first as the bike needs to come out of the garage so I can have a really really good clean up. It's getting impossible to work in there now. Ah, one last point. Gearing. I'm building this to try and crack 200mph, I was thinking about 17/41, giving 212mph @ 10,000 in 5th. Is that somewhere near gearing-wise? Thanks for looking Simon
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Post by gray7/11 on Jan 25, 2014 21:05:08 GMT
Really enjoying this build, keep the pics & updates coming..
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Post by colinworth79 on Jan 25, 2014 21:53:47 GMT
Simon nice to see the project is comming along . Think from memory im running 17/42 on my bandit and think i worked out it was 199@10k rpm . On this gearing it will lift the front wheel just by pinning the throttle in 3rd at about 80ish (on a private road of course )
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Post by busaash on Jan 27, 2014 14:32:28 GMT
nice too see lots of detail in your build thread , coming along really good . keep up the good work
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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 Feb 2, 2014 12:12:59 GMT
It's that time of the week again folks. Well, a bit later than usual as I had to wait an extra couple of days for the welding and lathe work to come back. Well impressed with the quality and 6 days to turn it all around is pretty impressive I think, especially as the guys alloy welder blew up and he had to farm it out to another company. Biggest shout out to Simon at SF Services - brilliant guy. Also got a 2bar 63mm gauge and braided hose made up with 1/8th fittings ready to screw straight into the plenum which I had tapped before being welded up Temp bolted the clutch cover on, still a bit of fettling to slot the breather hole inside, just wanted to see how it was going to look. Will have to take it off for powder coating this week Tried to get a shot of the pipework but never photos very well. Glad I spent a load of time getting this bit right, I love the honest bend from the turbo. Some of the one's I've seen are a really awkward angle... Well, the bench was getting so I couldn't find anything so I got the bike out and had a good tidy up. 2 hours later and it's still not great, but at least the floor and bike bench are clear. Finally got a shot of it outside Need a different pipe for the BOV (as I managed to drill the hole for the pitot on the wrong side so it has to face down now... And the clips I was supplied are too big So, got it back in and on the bench. Ordering a load more stuff for next week. Managed to get the chain cut and fitted, I thought I'd run a shorter wheelbase than first decided. Main reasoning is that its not for astounding 60foot times (final gearing is 16/39 = 212mph) just really for stability. Final couple of money shots: ... Next weeks jobs are: Dial cams in. Fit engine covers. Start (maybe finish) electrics. Fit chain link and adjust shocker. Fit rear brake pipe. Fit rear brake clevis and spacers. Chase up turbo flange (pipe already here) Sort out oil return from turbo. Thanks for looking' Simon
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Post by maggotbreath on Feb 4, 2014 15:52:11 GMT
Looks great, that set up is going to be a lot of fun!!
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Post by busaash on Feb 4, 2014 16:41:55 GMT
nice and tidy build and that ali welding looks bob on
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Deleted
Posts: 0
Reg: Apr 25, 2024 18:53:20 GMT
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Post by Deleted on Feb 5, 2014 20:05:29 GMT
good build good thread enjoying watching it come together keep it up oss-popcorn and give the coat back too the child oss-popcorn
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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 Feb 5, 2014 21:36:21 GMT
good build good thread enjoying watching it come together keep it up oss-popcorn and give the coat back too the child oss-popcorn It's the missus' old nightie
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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 Feb 7, 2014 18:35:44 GMT
OK, update for today. Been a busy boy, although it doesn't look like it... Got the new 90degree bend for the BOV, cut and fitted it (didn't take any pics...) Finally got the rest of the fittings and return pipe for the turbo, plus managed to track down the proper Volvo gaskets for turbo to manifold and also the turbo to exhaust. I've put pics on so you can use the numbers as reference. I used Stoneacre Volvo in Grimsby, the parts guy there, Gary, did a brilliant job going well beyond the call of duty ordering various gaskets until we got the right ones. I also collected the casings from the powderers. Starter side one cleaned up and fitted Quick turn-round on the clutch side as I was delayed getting it to the gloss black man due to welding commitments. When it came to cleaning it up ready for fitting I hit a problem Threads don't look too good there. A fair bit of powder overspill... Off down to the bolt place: Plenty of copaslip and working backwards/forwards, cleaning threads etc, and we have success! Worked it in from the top as well just to make sure: Sorted - and it's easier to screw in now than it was before! Bolt place only had 80mm cap heads so I had to thread them further down and chop them to the right size. All fitted and finally the MTC logo fits snug and tight on the side of the bike. Still waiting for the AN fittings to come for the scavenge return and breather. While I was on that side of the bike I thought I'd make a new torque arm and mount it. Also fitted the new longer brake pipe and secured it. Had to make up a new clevis for the GSXR master cylinder/Busa footrest hangers, looks a bit heath robinson but works perfectly well. Finally got the turbo bolted up, new BOV blanking plate cut to size and the first of the signal silicone hose piping fitted. Had to clock the turbo again slightly as the oil return pipe wasn't too happy at the angle I had it at. I've made the return pipe as long as I dare to let a bit of natural cooling occur. I don't think it will make a lot of difference but something is better than nothing. I've also got the carbs back off now to strip, replace bits, set float height and fit and new seals if needed. Hopefully more pics Sunday night. I need to get the cams dialled in, sort of hoping they'll do themselves... I need to get the wiring done as well. Sort of hoping someone else would do that... Thanks for looking. Simon
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Deleted
Posts: 0
Reg: Apr 25, 2024 18:53:20 GMT
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Post by Deleted on Feb 7, 2014 19:19:45 GMT
when your invisable helper has finished there send him over too me plenty too do here . looks really good hope you get your time,s you are looking for where did you get the chain from ? i guess off a roll as wheel base longer . struggling too find near me ?? keep it up oss-popcorn
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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 Feb 8, 2014 17:01:20 GMT
when your invisable helper has finished there send him over too me plenty too do here . looks really good hope you get your time,s you are looking for where did you get the chain from ? i guess off a roll as wheel base longer . struggling too find near me ?? keep it up oss-popcorn Thanks for the nice comments. The chain is the standard 750L, with an extra 10 links riveted with softlinks.
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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 Feb 8, 2014 17:23:54 GMT
Managed to get pretty much a full day in the garage today, took a couple of pictures as well. Got the carbs in bits, checked, cleaned and left upside down awaiting information on float heights. I know they have to be 2mm higher, so does that mean 12mm or 16mm? While there was a space in the carb area, I thought I'd slip in the yoshi-copy carb guard thingie for its 1st fit. Needs a little trim at the back... Time to get the home-made timing wheel on: And utilise these for the TDC stop... When used like this it makes a very cheap and handy stop Then set the zero (funny angle on the pic by the way) Just to make double sure I popped the DTI on as well. It was spot on. Anyway, loads of measuring, calculating, measuring, swearing and measuring later it was done. Set the tappets as well then it's time to say bye bye (until re-torquing time) Fitted the bloody expensive gasket and plug covers: ...And fitted it with the chrome buttons and spray bolts. Made up a gasket for the signal generator cover, also poured in 5 litres of ASDA's finest mineral diesel oil in the top. Final picture showing the colour scheme Should get the carbs put back together tomorrow if I get the info I need off OSS and the turbo facebook pages. If so, it's getting very close to looking mechanically finished. Still got the bloody wiring to do though Thanks for looking. Simon
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Post by captain chaos on Feb 8, 2014 18:18:46 GMT
I know they have to be 2mm higher, so does that mean 12mm or 16mm? Simon 16. Looking good.
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