GSXR fairing fitted to Curvy.

[Dacascos1]

Right do take one SV650 that you're not overly impressed with and are tired of being battered by wind when riding.

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps8140ae32.jpg

Now jump on eBay and grab some GSXR fairings from a 600 STAD for £45!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps91011f23.png

Have a little mock up of sizes with zip ties and welding wire .....

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsa9e39a2d.jpg

Double check for your space inside the fairing

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpscc3f72fa.jpg

Bueno, looks like it will fit!!

Next make crazy alien ears to support the front fairing do you can match the lower, like so...

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsf9784733.jpg

Now you're aligned and for this I mean use wood and zip ties!! But now don't laugh, these two offer alot of movement when positioning!!

Anyway time to make brackets here...

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps2f4f3754.jpg

And here....

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpscf02e758.jpg

Now remove your fairing and lift out you're newly aquired crazy alien spider thing like so..!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps8986d697.jpg


Weld up all these joints and place back on the bike and bolt up your fairing!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps10c442d6.jpg

Bolty bolty bolty bolt..



Right with that done lets get back to that exhaust as now the fairing is all bolted its sitting a little tighter than before and of yes the exhaust fowls the fairing inside GRRRRRR

A simple cut and rotate of 20 degrees with fix this...

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps7a68f8a2.jpg

And here the bracket must be moved, as well as loosening and unbolting the exhaust obviously but you already did that of course!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsab232bc4.jpg

Take time here to trim your rear lower fairing though as it really sets off the body I think!!

Now finally notice there's a bloody great gap between the fairing and frame.....
That's ok a little sheet metal will fill that, see!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsa08600b1.jpg

So it all fits beautifully yup yup yup

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps1c48dde6.jpg

And off out the garage she goes to bask in a little sunlight :o)

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpse8615faa.jpg


Not a bad days work I'd say and not hard either. To all the people (not that I had many replies) but to all I read of saying fitting fairing is to much work and really hard or impossible, I really can't be more honest than in saying it was easy!!!!

[rapidgaz]

Not a bad days work. Looks good too.

[MickeyHall]

Well done mate, what's next with he fairing?

[DanSp]

Youll be making copies of your brackets and selling them on then :p

[Dabteacake]

Good work there!!

[Mauler]

Youll be making copies of your brackets and selling them on then :p

This! Replicate and sell :D

[Mark-SV-UK]

Looks great. Has anyone done this for a pointy?

[Bibio]

very nice job. well done.

[Fruity-ya-ya]

Looking goooooood ;)

[Dacascos1]

Making it really isn't that hard for anyone even with basic welding skills but I guess I could do it again if someone wanted, just this time I'd do it prettier!!!

I still have a couple of infills to make at the weekend and to run the 'srad' system into my air filter. I think a 6mm tank rise will give the room for 52mm direct air feeds either side.

BUT.....

I am considering the resurrection of my last contemplation now I have a little more time on my hands if you can see what it is........?

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps6b073290.jpg

My little custom intercooler fits well

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps89449ee2.jpg

and will be accommodated well by the fairing so no pipes really on show!!

[Bibio]

yes turbo time.. go for it :-)

[Mark-SV-UK]

Wow bet that is gonna shift like **** off a shovel

[Dacascos1]

In fairness I know I'm very new to bikes, only have had my licence for a few weeks and this being my first bike but simply having the fairing it feels to me as if the bike is faster already, simple aerodynamics I guess or that I dare go above 6 now lol

Turbo charging is easy and I've alot of posts saying it can't be done or is to expensive to do, which is kind of what I'd read and been told concerning the GSXR fairing and I did that with all materials plus fairing for under £100, so lets see what turbo charging does shall we??!!
I think again I can do the full system at under £100 to be honest and unlike the other 2 I've seen this will be intercooled as running without an intercooler at such high compression is just crazy in my opinion

[jambo]

I don't think anyone said you couldn't fit GSXR fairings, the question usually asked is "Do any fit right on?" the answer is, as you've discovered than none are a perfect fit and some custom brackets are needed. Nothing too serious, but not everyone can weld :D

Turbos on the other hand are proven (by at least one of our members) to work just fine. Have a look on here, there's a chap who's been very happy with his results.

Bike looks good, keep up the good work :)

Jambo

[Dacascos1]

Well I must've read the no they don't fit and no turbos will blow the engine as the cranks are weak posts incorrectly then sir, for that you have my apologies ;)

[Fallout]

I think it looks decent. Glad you removed the GSXR decal too. :)

[Dacascos1]

So I haven't got dug in on the bike this weekend due to having to try and learn how to lean in corners and get my knee down in prep for my first race day on the 10th of September but I did pick up a couple of bits to help my little project along lol

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsfce65d63.jpg

A nice little solid state fuel pump, clean and clear stable 4psi as after looking into the bikes fuel system I found the diaphragm vacuum pump which will never support positive pressure!! So that's fuel delivery sorted for £15!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsdea24b2a.jpg

And I also grabbed some nice shiny pipe for a high level exhaust, not bad for £20!!!!

Fingers crossed I'll be on it next weekend and have this turbo done, I just need one more piece of the puzzle!! Just got to did the time between learning bike control, gaining confidence and then building stuff for the bike haha no rest for the wicked!!

[Knobby]

Ditto........ I want me one of these brackets and fixings please !!!

[Dacascos1]

Then pick up the fairing, some 10mm steel tube and a 2 metre length of 20x4mm steel add some time and bueno!!

[Knobby]

hmmm ok will make inquiries.
I take it the clocks needed are SRAD clocks?

[Dacascos1]

No not at all, it's all SV just with the outer coatings of an SRAD!! Simply just the skin, the bracket made to support the front fairings and nose I welded to the support for the cluster as a baseline for symmetry.

[Dacascos1]

So looks like this week I can weld the intercooler up whoop whoop, now if I can just find the last piece of the turbo puzzle... Wish me luck

[Mark-SV-UK]

Whats the last piece?

[Dacascos1]

Last piece is the difficult part I'm afraid and of course!!

Turbo chargers work on a gravity return, however the SV gives little space to fit a charger neatly least of all to mount it high enough to gain a nice even rtetun flow from it. Thing is if the return line from the charger was to fill with oil and back up it would cook, jam and damage the turbo, so as appose to the common and easy route of turbo returns we have to take a second look.

Now this is where it gets complicated as we need a pump of sorts that can run dry(ish) without causing adverse wear yet still run constantly and be capable of moving large amounts of high temperature fluid. Which in short is alot to ask of a pump, especially when you're also asking it to not require the fluid passing through it to be needed to cool it too!!!!
I have seen scavange pumps that are geared into the stock oil pump but they are priced at sqillions and squillions of pounds so thats out, an external oil pump is an option but they require constant flow of fluid to cool them so thats also off the design table, Oh and did I mension I refuse to pay more than $150 for this conversion so I have to pull something out the hat fast!!

Though I do have, a cunning plan..............

[Dacascos1]

Hmmmmm.....

So as I've been lazy of late when it comes to my bike, one due to practicing for my first upcoming race day and second due to work commitments, I decided to not go out to practice tonight but instead to have a sit stare and contemplation on this turbo conversion and all I came up with was 'hmmmmm oh crap'!!!

So it turns out my lovely fairing I fitted is going to cause hell and all issues with my turbo pipe work!!
The charger, cooler and hoses are fine they have plenty of room but and it's a big big BUT as the space at the bottom of the fairing due to the nice fit leaves ever so little space for the piping!!
Always gotta be something huh!!!

Still on the plus I guess, I've almost worked round the issues of pressurising the carbs and a second option for the turbo oil return so it's not all doom and gloom just the space for pipes is AWFUL lol

So.... I think Sunday will be the start date for the conversion. Wish me luck!

[nikon70]

good luck on sunday, good day to do it as it will be raining... lots of photos too please :)

nice garage setup too :thumbsup:

[Matt-EUC]

+1 lots and lots of photos

[Dacascos1]

Lol pictures pictures pictures ok ok ok!!


Right so after sitting on my butt on a cold garage floor with a coffee and smokes I've come to the conclusion I CAN make it fit!!!
However the exhaust from the turbo is going to protrude from the bottom of the fairing by 1.5 inches for about 8 to 10 inches........ Is this going to look like ass??

Opinions appreciated please

[Dacascos1]

And it won't be shiny as the exhaust around the engine will be heat wrapped so not pretty at all....

[nikon70]

If it is wrapped in red tape to match it won't be noticed.

Plus they will be looking/listening to the bike as it storms past them, I doubt they will be concerned with the pipe underneath

[Dacascos1]

That's the thing the wrap will probably be hemp as passed experience has shown that as the best as you can soak it first stretch it, wrap it on then it shrinks to size and stays so tight it's great. So against wont be pretty....

Plus the bikes not staying red lol I have a friend of a friend who does vinyl wrap, he's priced out at between £60-100 to do all of my bike so got to design what I want for that at some point too.

To me the exhaust is a big issue, to the extent it's really stopping me from starting, plus I may have my bike at JAE for a friend so need it to look picture perfect. Little stressful!!

[nikon70]

Extend the lower fairings?

use multiple thinner pipe work that channel from and into one larger pipe?

Use flat channel pipe work ?

[Mark-SV-UK]

Will deff look good and be rapid

[Dacascos1]

I don't have the space for thinner pipe I don't think but will check as may be an option!! Thanks for that one!!!

Flat pipe is never an option for exhaust due to the way exhaust moves inside a pipe, it actually rolls round the putter edge sticking causing an almost boundary layer and this with the heat of expansion draws the exhaust from the pipe at the initial. Well till it cools down to a point it can no longer stick then you get the turbulence lol

[nikon70]

Any update on the pipes?

[Dacascos1]

Ok so here goes, yesterday I was supposed to start but as I got my first one piece suit it seemed rude not to wear it and go riding or should I say try and scratch my sliders lol so nope nothing done yesterday at all!!!


HOWEVER....


.....today is a different story. Got back from work and here I go, straight to the garage with my smokes and a corona, so it's begun!! Got a few pictures already so going to pot them up now...

[Dacascos1]

Right so here we go..... (Please remember this is a mock up to ensure it all fits and works so don't be expecting lots of shiny stainless yet!!!

First remove the right side fairing, I've left the other side on as I need reference for the space I have for the turbine exhaust which is the current dilemma as stated.

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsed6c7ae7.jpg


Next chop up exhaust!! Yes I did say chop up your exhaust you did read right!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps71e1f6df.jpg

Next cut and trim tiny the awesome U bend already available in the exhaust, what a win!!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpse0934f9f.jpg

Next, run the exhaust as close to the body as possibly and weld in said U bend!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsa5ebcd56.jpg


Yup that's as far as I got before I had to come in and pee so give me an hour or so for the next update lol


Oh and wish me luck!!!

[Dacascos1]

Ok so here we are again finally my bed time so a quick update for you.
Did a few hours in the garage amongst chatting and eating so I can at least say some work was achieved!!!! And for this reason I will start by showing my first sponsor of the evening lol

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps4569161f.jpg

So back to work and here we go...

We need to keep the pipes equal length so we can cut down on backing up the pipes so using the U bend supplied by Suzuki we can turn the front cylinder exhaust round and feed it in with the pulses from the rear no problem as so...

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsdbde5e12.jpg


Once matched and clamped up we can extend that line from the rear back forward giving us the turbo exhaust feed again as so...

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps8f20c53f.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps9466df3f.jpg


Time to fashion a flange for the turbo and weld said pipe to it...... This flange is as per turbo as they all have different foot prints.

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps6b0f1b6a.jpg


Next cut lots of angles cos your too cheap to but in bends from guess works and the shops are shut!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpse5c18368.jpg


Weld it up once correct whilst pretending you're not almost out of gas.....

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsd939c608.jpg


Now to relax and eat a kebab wrap and chips ***think big smiley face when this turned up for dinner!!!***

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps5753f948.jpg


Now weld it to the front facing exhaust feed and notice that is way to an aggressive angle and that you'll have to change it tomorrow D'oh!!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsc76890f3.jpg


Fairing fits though......

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpscd9beee3.jpg




And that is all for tonight lol!!!

[Mark-SV-UK]

Well done fella you been a very busy bee

[nikon70]

Awesome progress!
Lovin your work dude!
I spent my evening painting my front gate in lovely Hammerite black with a cheap high density foam roller - how satisfying (not).
Then went and fed the chickens, oh look free eggs. :)

[Matt-EUC]

You should make and sell kits for this.
Then expand your market to other bikes.

[Simon-SV-UK]

that looks really good, I like it

[Dacascos1]

In fairness bud, if this all works out to plan and I can get a reverse charger, I'll have a jig to work from to make kits if people really do want them but thats 'if' people really do!!
Its not hard work its just alot of cussing and sitting on my thinking stool with a box of smokes before starting at it all again but lets not jump to far ahead, I'll finish it forst then we'll look from there!! I still have to fix my half inch mis-measurement thats making my pipe touch my fairing yet!! but this is why we make everything in mild cheap steel first (learnt that lesson the hard expensive way!!)


I'll try and get at the bike again tonight, I'm supposed to be out on it again this weekend so I have a bit of a deadline to meet which shouldnt be a problem but if Murphy is in town with those laws of his then who knows what could happen!


Plus I've still got to get the bike all painted and wrapped for the stand at JAE on the 12th and bike night at Ace Cafe on the 6th, busy busy four weeks for me so I must have this done by the weekend latest!!



Well done on the gate and eggs Nikon ;)

[Dacascos1]

Well I'm guessing the reall question on everyones mind besides is it going to blow up is how much is this going to cost in reality so here goes.........


10 - T15 turbocharger
12 - 1.5" 2m steel pipe
15 - 2x 2" 90* steel bends
8 - steel sheet for turbo flanges
14 - fuel pump
12 - intercooler
5 - flexi hose

The first number on the above is the cost in GBP for each thing, just I dont have a pound sign on my keyboard!!

I'm still going to need a few pieces of silicone hose to connect everything but thats pretty much all of it I think, oh and an oil feed pipe and return but I've not looked at those yet!!!

[Mark-SV-UK]

So how much has this cost ya and would you need to uprate internals and extra load on engine? Ive been into turbo cars for years and know its cost me a small fortune lol 320bhp mr2 turbo and nissan 200sx s14a 220bhp. But bored with cars now and into mynbike I a massive way now so car has been forgotten about and only covered 800 miles in 1 year lol

[Dacascos1]

Well I did my time specialising in Japanses performance cars, TA cars, EDC cars, 200mph club candadites etc so have a good insight I guess. Though to be honest bud 320hp on an MR2 turbo doesnt require anything internal bar pistons and a head gasket for safety, obviously the turbo, intercooler, exhaust and a remap as without a map pushing 300 'cleanly' is an issue so either you overspent or, well I dont know.
220 on an S14 is barely stage one so should've cost chump change to do as you can run everything standard even the exhaust at that power as is only a 16hp hike on stock so I must admit I'm a little confused where all the money went?? No disrespect meant here, I'm just confused and concerned you've been badly advised is all.


As for the additional load I'm not massively worried as it seems to be at load at very high rpm that snaps cranks, over reving always hits engines hard. Personally my concern is the 12.5:1 compresion ratio!!! adding extra pressure to that is going to run a high chance of det but I'm working on that one.
The best thing with bikes in my opininon is that you dont need those big power hike numbers, a 6hp increase you will feel without question so a few psi of boost is all thats going to be needed at start to get that torque up and accelerating faster and with such low boost det wont be a huge issue either

[Dacascos1]

You should make and sell kits for this.
Then expand your market to other bikes.

I'm actually going to be giving my friend a hand turbo charging his R1 once its all back together lol!!

[nikon70]

why don't you just mix up some nitro in with ya petrol, won't that be far simpler? :thumbsup:

[Mark-SV-UK]

As said I done all the things to mr2 plus everything was apexi with avcr and safc2 plus cusco fully adjustable suspention it was a road/track days toy and yep 200sx is pretty standard bar exhaust induction and few other tweaks bit is an audio show car so all money went on audio. I was just asking about internals on sv as know its not easy job thats all :-)

[Dacascos1]

why don't you just mix up some nitro in with ya petrol, won't that be far simpler? :thumbsup:

Hell no!!! next someone will say water injection..... all these additives and mixes are top offs, its like nitrous for instance. You build your vehilce to what you want then nitrous is either an anti lag or just the icing on the cake, get the build right then worry about the additives. Well thats my opinion anyway!

Its also what happens if you run out for whatever reason? do you just have to ride real slow (as we always do Mr Osifer) till you have some more? Nah build it right then look at icing

[nikon70]

Hell no!!! next someone will say water injection..... all these additives and mixes are top offs, its like nitrous for instance. You build your vehilce to what you want then nitrous is either an anti lag or just the icing on the cake, get the build right then worry about the additives. Well thats my opinion anyway!

Its also what happens if you run out for whatever reason? do you just have to ride real slow (as we always do Mr Osifer) till you have some more? Nah build it right then look at icing

hahaha was only kidding!!!!

build it right - that's one of my lines, along with measure twice cut once, and it's all about the preparation work that takes the most time...

[Griff-SV]

This thread is brilliant! Cracking pictures.

[Dacascos1]

I just think if you're using additives to stop det then theres an issue to be addressed somewhere in your build but some people live/swear by meth nitro or water injection




If theres anything Along the way that anyone wants more indepth pictures of or explaination, I'm not the greatest photographer or smartest guy ever but I'll do what I can

[nikon70]

Hey don't knock yourself, we're all smart in different ways ;) some more academic others practical. In my books you have both based on your stunning welding skills ;) and what you've done thus far :)

[Dacascos1]

So..... After stripping out curing everything off to start again due being a half inch out I got most of the way through it and then the bike bit back!!!

I got far enough I guess, I started from scratch and got all the pipes back on

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsb7023b23.jpg


I had to cut alot of angles in on the rear pipe to get it over far enough to accommodate the return pipe from the turbo

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsa7c2615b.jpg


It's getting quite cramped in there isn't it!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpscf782029.jpg




BUT then the bike bit back in the guise of launching a piece of metal into my eye as I lifted my mask......

So the rest of the evening was spent at A&E waiting for the doctor to stick a huge needle in my eye!! Yay me!!

[Mark-SV-UK]

Oh dear not good hope its not to uncomfortable now

[Braindead101]

My sympathies on the eye! Brilliant thread, just loving it!

[nikon70]

ah the A&E eye doctor... been there many a time, the lovely dye they stick in there, the needles, the turning your eye lid inside out... those are the days...

well I hope it's nothing too serious...

hope you're ok!

ps. great work

[Mark-SV-UK]

Makes myneyes water just thinking about needles around my eyes

[Dacascos1]

Thanks guys, luckily god graced me with a spare lol!!

Well I'm back from work so lets start at all this again, in the famous words from Kenan and Kel "arh here it goes!!"

[Dacascos1]

Ok so here we go its food time so also update time!!

Right so finished welding up the manifold so to speak

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps50fb19a7.jpg


Now to start on the down pipe from the turbo so first make a bendy bit cos I'm to cheap to buy one or cos it's to late in the day!! Oh and a flange!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps29287564.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps2cf3a101.jpg


Fit the flange and add the bendy bit made....

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps26906663.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps701d21d2.jpg

Now lets see if the turbo spins up shall we, it's going to get loud!!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/IMG_6209_zps9b227eca.mp4 Edit: seems the video link from photobucket doesn't work!!

Whoop whoop it works!! The worlds largest amount if exhaust leaks but hey nothing's on tight yet!!!


New exhaust outlet as I've no idea on a high or normal level so just a pipe right now!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsaa2131d0.jpg


Next!!!

Lets look at the carbs and see what to do next!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsd322a0b1.jpg


Thing is we've got to get the air in as equally as possible to feed either carb so time to make a plenum.... Oh and no sharp edges as that will cause the airflow to become turbulent causing static and vacuum areas, this equals BAD so again lets see what can be done within everyday prices!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsbf6cbbd3.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps2d6b249e.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsfdc30fab.jpg


Getting a little tired so employ a mate to help, cheers Larry!!......

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps01f9df58.jpg

And 'poooof' as if by magic there's a plenum chamber flowed well given the intake point!!!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsb76e8752.jpg


Ok so we're getting there, so easy stuff time. New fuel pump, out with the vacuum diaphragm pump and in with the elecy pump YAY!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps56c94578.jpg

And position

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps4c692ed3.jpg


That's it for tonight, been busy busy. Hope it's a good read

[Mark-SV-UK]

I cant see the you tube vid link. This is one great how to :-)

[Dacascos1]

It's not YouTube, it's on my photobucket but won't play which is weird. It's just the first start up, lots of exhaust leaks, no muffler but shows the turbo spinning. It was exciting for me!!

Now it's just the intercooler and pipes to sort, the finish the fuelling, carbs and I think that's it tbh but I'm away Friday onwards so no updates this weekend I'm afraid!

[Mark-SV-UK]

Wheres the like button :-)

[Tomor]

Click this (http://i1290.photobucket.com/albums/b530/Dacascos1/IMG_6209_zps9b227eca.mp4) for the video

[nikon70]

Kel like orange soda!

[Dacascos1]

Still working on idea's for the muffler, high level or stock position. To tilt it up aggressively or go with the angle of the bike...... I have an old Scorpion oval stubby to fit but idea's on where and angle would be appreciated!!!

And yes 'kel loves orange soda' hahahahahahahaha

[nikon70]

I like the aggressive high level position in line with the rear end....

[Dacascos1]

See I like the look of them too but I have a couple of girls that regularly ride pillion and they've said (and I agree) that their right foot will cook with and exhaust that close.......

So question to those with high level exhausts would be, i guess, is this true? does the pillions right foot get hot??

I collected a friends ZX6r the other day as he has no licence yet, fingers crossed that today he passes though, and his stock position exhaust was cooking my heel. I always ride on my toes as told too, so not flat foor but even so my foot was baking. I wouldnt want anyone to ride like that, thus the question!

[nikon70]

hmmm well i havn't found my heel cooking and I have a high can, not totally high but enough that my heel nearly touches...

having pillions and high levels could be a problem, you don't want any injuries! A&E burn unit no no no!

might have to stick to stock level then, or under seat ;)

[Owenski]

Druel

[nikon70]

*rubs hands on knees*

*phaw*

*wolf whistle*

I just love a thick solid pipe (that sounds wrong)

[Dacascos1]

So unfortunately I only got an hour or so in the garage tonight due to other commitments so this update is a little brief but I have a few pictures accompany it as usual!!!

So back to the plenum chamber, we left of yesterday with just a plenum which is no use by itself so on goes the inlet to said chamber and a few vacuum ports which will be needed for wastegate control, boost gauge and for positively pressurising the enrichment pin in hope that will aid our on boost fuelling

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps8424e00b.jpg


And another angle....

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps6eb4b972.jpg


I was going to make another bend but then it dawned on me that if I make it all solid I'll never get the cooler line out, so in comes a randoms piece of 80* hose that was on a shelf!! I think it was from a previous WRX engine rebuild I did but not to sure!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps58554873.jpg


You can see where the intercooler cold pip is going to run inside the frame and behind the rad (it's the random pipe hanging down if you didn't guess!!!

Oh and I started to plumb in the lecky fuel pump too with a new bracket too!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps30f491cc.jpg



The best thing is the silicone pipes holding the plenum to the carbs are the original rubbers!! Little crafty trimming and they matched up just right so that's a win!!!
As I said before though I'm out from tomorrow evening till about midnight Sunday so no more updates till next week but be sure Monday night I'll be back at it!!!

[nikon70]

I like, I like a lot!

[Dacascos1]

Ok so I sat on my thinking stool with my smokes considering the exhaust mounting then side tracked to the rear....

So a tangent started and off it came lol

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsffd591d9.jpg


Then make some box section cos again it's late and the shops are shut and trim it to just over 3/8"

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsa93194af.jpg


http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps15790075.jpg

Cut the rear frame and well these 3/8" box sections in (24mm x 18mm)

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps3640f43c.jpg


Add a little paint

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsa967a912.jpg


And done, before and after

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps3cbc4603.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps141b6660.jpg


Looks great I think, far more aggressive!!! The issue is now the side infills don't fit so some wiring and a relay must be moved but hey a small price to pay I think

Stretching wiring!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps82f13c46.jpg

[Matt-EUC]

Looking good.

[A_Yam]

watched

[Mark-SV-UK]

Nice jack up mate

[nikon70]

I must say I am very excited about this progress and scream like a 16 year old girl each time a new post is made... *swoon*

[Dacascos1]

It already sat high at the back thanks to the 'very' short dog legs we made at work but ideally wanted that race bike almost dirt bike (I guess) rear, so yup a little bit of a tangent from the turbo conversion but a welcome one especially with my bro on the grill cooking up steaks and chicken!!

This jack up though has got to be one of the easiest conversions for pure looks!!

[nikon70]

Simple such a small tweet what an impact it can have.

[Dacascos1]

Ok so I'm sitting at work about to take my lunchtime nap whilst my intercooler is being welded up!!! ***Thanks Dave*** I have no idea how to TIG ally so again whoop whoop for Dave!!


Just looking over a schematic of the carbs we run and seeing where the pressure lines will run.

I'll be finishing the project this weekend and obviously there will be all the photo's of where things go, how to make this and that then the finishing statement as usual, generally staing that I am one big tired tiger but.............

AND ITS A BIG BUT....

Do you all want me to show you where it all goes and WHY AND HOW it works and why we use the bits we do or just picture editiorial?? I dont mid either way so up to y'all really so let me know!!

[Dacascos1]

And yes yes I'll post up the price for the conversion too, looks to be under 150 once I've ordered the exhaust wrap so thats not bad but we'll see when I total it all

[nikon70]

that's a bargain price!

Yes - where it all goes with picture editorial
Yes - WHY AND HOW it works and why we use the bits we do (secondary to the editorial)

[Dacascos1]

So ok I've been lazy this week, me and my boy finally built the oomph to get back on the gym so that's taken a lot of my time and the painful aftermath!

Right well as I said, the wonder that is Dave sorted the intercooler for me as you can see

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps47c63618.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps9db3167f.jpg


http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps6b28286b.jpg



And whoop whoop, the finished item... Gotta love his skill!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsfd17ce0b.jpg



So that's all my bits together really, just heat wrap and we're pretty much done would you believe!!! Not bad for two weeks!! But for this morning my day shall smell of flux as its wire tidy time BORING :(


http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsbd05dbbe.jpg


Should be finished tonight or tomorrow lol

[Mark-SV-UK]

Nice one mate

[Dacascos1]

Ok so next dilemma. I looked at the soldering iron and thought 'screw that' so started back on the engine lol

Ok so I have to fit a return feed for the turbo, gravity fed, that enters the oil system above the oil level.
So yup found that and all good on space. Next remove engine casing so we can cut a big hole in the side and ensure none of the filings get left in there.

BUT THEN THIS HAPPENED.........


http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpscc3178fa.jpg


Yup that's right, the lower front of the casing (as you can see) is a WATER JACKET AAAAAARGH!!!!

So I am now sat on the couch indoors sulking and trying to think a way around this next issue :(

Anyone who wants to bring me ice cream and smokes to cheer me up feel free!!

[Dacascos1]

Ok kids so here goes, finally got over my man strop and hit the garage again. I'd like to take this moment to point out that no one brought me smokes OR ice cream which I'm a little hurt about but hey the story goes on......

Right so...... Sat on the sofa I heard a knock at the door and it was the postman with my heat wrap so figured as I was up I should make the most of it and get back in so here's a pic of my heat wrap as its awesome!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps0c48da0b.jpg


Then it was off with the front case, if I wouldn't go in from the front I'd damn well go in from the side so off and a big hole cut as low as possible to allow the oil to gravity feed

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsc5e4f13b.jpg


If you look closely here you'll see there is a lip at the top where the pipe enters the case, this is to lower the chance if oil draining across the case to back flow into the turbo return pipe. Then on it went whoop whoop!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps11eaebcb.jpg



Next I got to wrapping so exhaust off and time to get wet!! Always soak your wrap first, it'll go on easier, you can stretch it and as it dries it'll tighten up round the pipe.

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsf556289a.jpg



And the pipes on and with the return feed too

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps7fc24e53.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps41c45208.jpg


Next cut shape and weld one cold side pipe for the intercooler

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps9aa6efa1.jpg



Then a hot side pipe to feed from the turbo to the cooler

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsabc93ba6.jpg



Put it all together... Looking good!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps09b4376a.jpg




Then a little test fit either side!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps501367a8.jpg

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsbd837985.jpg




And that's as far as I've got but I'm still at it!!!
Not to bad for two weeks to the day!!!!

[Mark-SV-UK]

Love ya pipework mate very clever

[nikon70]

first glance I was like, now why on earth have you routed the pipework like that... on closer inspection it all makes sense :)

good work.... can't wait for the test ride you're going to let me have ;)

[Corny Gizmo]

Hi Ryan here,

long time reader, first time poster, in my opinion it looks like the dogs danglies! im here for test ride dummy if needed haha!

[Dacascos1]

So everything came together then just had to start testing....... So first finish wiring up the starter relay I moved!!! (Yes it's messy in there!!)

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps269afdb2.jpg


I did this as jacking up the rear meant my infills no longer fit so I had to tidy out under there, looks prettier now but bad pic I guess

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsf7e34b8d.jpg


For giggles here's how I set it up to test.....!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps4584793f.jpg



So the carbs didn't blow out under 4/5psi of pressure from the fuel pump but strangely my bike fires straight up now and I mean click brrrrm!! The fuel pump is a great modification even for non boosted bikes in my opinion, no three turns of the engine just click brrrrm it's great!!
So yes carbs held the pressure fine and no choking the system.

First fire up was a nightmare though, smoke everywhere from the exhaust wrap then watching the turbo at idle it was struggling to turn. Admittedly I expected it would a little given its designed for a 1500cc and is only taking 300cc pulses at idle but this was seriously slow.....
However the wastegate was wide open as I've not fitted the custom actuator nor made it yet, so fire it up again and yup turbo spins ok at idle, slow yes but as I said that's expected!



Right now the more important part, the carbs are all piped up for increase dynamics

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zpsb9a0690a.jpg


so it was throttle time......


Wait for it....


Wait for it....


BRRRRRRRRRRRRM to 9k throttle closed 1psi of pressure and......


PFF-FT-FT-T-T yes we have turbo chatter!!!!



No flooded carbs, no dip off, nice clean jump threw the range and chatter on the release!!! I'm so excited, yes the next jump is to put it all together and take it for a test rude but baby steps, baby steps!!!


And so in my excitement I made an exhaust flange for my Scorpion stubby lol

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps647cf3a5.jpg


Hope you're all enjoying the thread :)

[nikon70]

Loverly progress!!

[Mauler]

Nice!

[Dacascos1]

Ok my bad, I just looked through and I got pictures muddled up. The picture I listed as a test picture was the test for the return feed lol this is the correct picture!!!!

http://i1290.photobucket.com/albums/b530/Dacascos1/photo_zps347de039.jpg


That's better!! In this one the intercooler etc is attached!

[Dacascos1]

Ok so no real work has been done since monday as I've been working on other projects BUT last night it was time to strip all the fairing off my bike and sed it to the vinyl mad to make it all one colour!!!!

It'll all come back in my chosen base colour so I can put it back on then ride to him and have the overlay design done. This way he can do it at his leasuire without rush and thus costs me less!! HOWEVER after sending it all I realised I no longer have a tank so how am I going to test my bike...........................

[nikon70]

Doh!

[Mark-SV-UK]

Fill a container and whack a pipe in bottom onto fuel line

[nikon70]

His name is not bodge it!

This is not scrap heap challenge ;)

[Mark-SV-UK]

Pmsl just an idea