Author Topic: project build up *turbocharged*  (Read 47916 times)

0 Members and 1 Guest are viewing this topic.

Offline Steve in Sunny Fla

  • Industry Member
  • I Need a Life
  • *
  • Posts: 7547
  • AREA: Southeast Area
  • COG#: 6977
  • Membership Level: Active
Re: project build up
« Reply #25 on: October 20, 2012, 10:25:57 pm »
I can see this is going to get interesting  :great:  Steve
C-14 ECU flashing for performance and rideability enhancement
C-10 Carb work , cams, & performance enhancements
 " Modifications for sport-tourers, BY a sport-tourer"
https://sites.google.com/site/shoodabenengineering/home

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #26 on: October 20, 2012, 11:21:43 pm »
 >:D an d this came in the mail today...





turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #27 on: October 21, 2012, 12:51:43 am »
Max, what are the specs on the turbo?  Mainly... what size is the comp wheel?
Where ya gonna mount your squirt?  I put mine in the tail section, but I reckon that will depend on...
Are you going to run spark and fuel or just fuel?
If spark, what are your plans for a trigger?  Connie's set up WILL NOT WORK, I promise. THere's no way. The squirt just cannot decipher her pulses no matter how you try.  I have tried numerous trigger wheels and pickups and might be able to help.  If you go fuel only and you want to trigger off the flyback from the #1 coil... don't do it till you talk to me or you'll fry the squirt.  DAMHIK  :-[  You've got to add in a resistor and a diode to protect it.  That info is in the megasquirt forums, but I didn't find it until way too late.  Matt soldered in a new old school resistor into my unit (kinda sloppy since everything else on the board is SM, but it works).
Which ZX6 t-bodies did you get? (Year model)  They are easy to space out in the center (about 10mm IIRC and then extend the foot between the adjusters), but will require custom cables to operate since the drive is all on the left side.  Lots of ways to skin that cat, but early round Z1000 or even Z750 t-bodies have center cables.  WHile there are plenty of other issues getting them to fit, they are probably the better choice overall.  The later Z1000 T-bodies have the oval intake sides and they are too hard to keep a clamp on under boost.
Are you gonna have any forged pistons made?


EDIT TO ADD:
Oops!  I wrote this up earlier today and failed to post it.  Now I see you have the later model Z1000 oval t-bodies.  It'll take some good clamps to hold em at ten psi.  I use these...
http://www.ebay.com/itm/intake-intercooler-turbo-pipe-t-bolt-clamp-1-25-x-2-/200806957520?pt=Motors_Car_Truck_Parts_Accessories&hash=item2ec10701d0&vxp=mtr

THe Z1000 t-bodies will have to be narrowed, which is much tougher than making then narrowing the ZX6 ones, but it can be done.  I have a couple of pair to prove it. 
« Last Edit: October 21, 2012, 12:56:55 am by Rev Ryder »
Fortis non Ferox
 Shafties Can't Wheelie

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #28 on: October 21, 2012, 12:59:01 am »
Do you have a controller for your WBO2 sensor?
Fortis non Ferox
 Shafties Can't Wheelie

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #29 on: October 21, 2012, 04:20:34 am »
rev, these are throttle bodies from a 2006 zx 636 limited edition, i simply ordered the microsquirt, dont recall exact specs on the turbo, but i know it will support a bit over 200hp (more than i care to make) and i will do fordged internals, but not this week.
turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #30 on: October 21, 2012, 04:37:19 am »
oh yea...no wide band yet...maybe next week i will pick up AEM wide band o2 set up...this week i have that Italian disease call myfundsalow  :o
turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #31 on: October 21, 2012, 04:44:45 am »
rev, these are throttle bodies from a 2006 zx 636 limited edition, i simply ordered the microsquirt, dont recall exact specs on the turbo, but i know it will support a bit over 200hp (more than i care to make) and i will do fordged internals, but not this week.
Yeah, I would suspect even a small GT20 would support 200+  I have a GT15 I've been contemplating trying.  It's smaller than my current antique and inefficient T-25 both physically and compressor wise (49mm versus 53mm), but will still support over 200hp.  I have no forged slugs nor money to get a set, but when you're close to getting some, let me know.  Maybe I can come up with cash for a set too.  They often will give a little discount for more than a one-off.  There's nothing off the shelf that will work it appears.  I made LOTS of calls in 2007-8.

On the Throttle bodies, I don't trust the oval openings.  I haven't actually tried my set yet... mainly for this reason.  It's amazing how much pressure 10 psi is when you're trying to contain it.  With the clamps I have (same as I posted) they might work.  Or you could make some spacers to fit inside the clamps and kind of fit around your hose.  The problem is the sides don't get clamped real tight.  WIth 10 psi on an air hose and regular hose clamps I had leakage on the bench and so abandoned my Z1000 t-bodies (which have the same oval port design).  I was not aware any ZX636 had gone this way.  I guess I haven't been paying attention.  You could make a shim of sorts to help woth the clamping force IF you have a problem.  I was able to hold 7 psi on the bench no problem.  Just an FYI.

« Last Edit: October 21, 2012, 04:46:24 am by Rev Ryder »
Fortis non Ferox
 Shafties Can't Wheelie

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #32 on: October 21, 2012, 05:10:16 am »
these particular t/b's also have 2 sets of butterflies, one mechanical, and one fly by wire that are in the oval section....i think i might have to gut those out...lol
turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #33 on: October 21, 2012, 01:30:07 pm »
these particular t/b's also have 2 sets of butterflies, one mechanical, and one fly by wire that are in the oval section....i think i might have to gut those out...lol
Yes you will.  Pull the flies and the shafts.  Then the holes can be epoxied or sealed with bolts.  If one had some really small freeze plug style caps they could press in, that would be ideal.  But mine are simply JB Weld-ed shut with a slight overpour on each side and I have never had one to leak or blow out in five years.
Fortis non Ferox
 Shafties Can't Wheelie

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #34 on: October 21, 2012, 05:24:50 pm »
these particular t/b's also have 2 sets of butterflies, one mechanical, and one fly by wire that are in the oval section....i think i might have to gut those out...lol
Yes you will.  Pull the flies and the shafts.  Then the holes can be epoxied or sealed with bolts.  If one had some really small freeze plug style caps they could press in, that would be ideal.  But mine are simply JB Weld-ed shut with a slight overpour on each side and I have never had one to leak or blow out in five years.

so when are you gonna be able to get back to your turbo bike?  :motonoises:
turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #35 on: October 21, 2012, 05:44:02 pm »

so when are you gonna be able to get back to your turbo bike?  :motonoises:
I reckon I'm ready.  THere's at least a LIL resistance on the home front.  Personally, I wanna swap in a ZZR1200 and turbo/inject that, but no way can I get the funds from mama for that project AND rebuild the bike from scratch as it is.  Still looking at options I reckon, but my best bet is probably buy a bunch of stuff plus fix and paint what I have that's reusable.  I'd say I'll probably get on it as soon as it's too cold to jetski out in the Gulf to fish.  I reckon 2-4 weeks that'll happen.
Fortis non Ferox
 Shafties Can't Wheelie

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #36 on: October 22, 2012, 04:19:39 am »
 :s_hi:



turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #37 on: October 24, 2012, 03:30:23 pm »
let the fun begin!!!  >:D



turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #38 on: October 24, 2012, 07:05:45 pm »
You will need to drop the pan and modify it as well in order to use the oil pump to oil and scavenge from the turbo.  I already have all the work figured out and can provide it in pictorial form with annotations.  Some drilling and tapping required as well as plugging the old cooler output line holes.  THey are simply bolt thread and NOT pipe thread even though it SEEMS 1/4" NPT is a fit, it is not and must not be used. DAMHIK  I just know.  :-[
Fortis non Ferox
 Shafties Can't Wheelie

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #39 on: October 24, 2012, 07:07:20 pm »
OH, I also found the COncours exhaust gaskets to not seal well enough to hold the pressures of a turbo.  I went to some Yamaha gaskets that cured the problem.  I'll dig up pics and part numbers for ya.  I keep a spare set, but they re-use once pretty well.
Fortis non Ferox
 Shafties Can't Wheelie

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #40 on: October 24, 2012, 07:18:43 pm »
« Last Edit: October 24, 2012, 08:31:33 pm by Rev Ryder »
Fortis non Ferox
 Shafties Can't Wheelie

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #41 on: October 24, 2012, 08:34:42 pm »
so i started on the fab...and ran out of wire for the welder...FUUUUUUUUUU  :-[





turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #42 on: October 25, 2012, 05:36:47 am »
well, i could still cut to fit things fairly close, and i also made a heat shield for the turbine housing out of a stainless steel bowl...lol









turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline wile_e_coyote

  • Scooter
  • ***
  • Posts: 289
  • AREA: Southwest Area
  • COG#: 10316
  • Membership Level: Active
Re: project build up
« Reply #43 on: October 26, 2012, 12:06:07 am »
Quote
i also made a heat shield for the turbine housing out of a stainless steel bowl...lol

That is just genius. :beerchug:

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #44 on: October 26, 2012, 01:01:24 am »
more progress after a pit stop at the welding supply house today!  :)





turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #45 on: October 26, 2012, 02:18:26 am »
Deja vu indeedy.
Watch out for fan clearance Max.  Even mine required modding the fan housing a skoche and your's looks further forward to me.
« Last Edit: October 26, 2012, 02:20:28 am by Rev Ryder »
Fortis non Ferox
 Shafties Can't Wheelie

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #46 on: October 26, 2012, 02:34:45 pm »
yes, i too am wondering about the fan issue, but i dont have a spare fan to slap on for fitment like to do the radiator mount   ???
turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #47 on: October 26, 2012, 11:20:07 pm »
It's low enough you may not have to do much.  THere is a single bar coming down in the center on the fan mount, but your pipes MIGHT be far enough apart for it to fit between them.  Mine were not and I had to cut and fab a little reinforcement for that portion of the fan mount.  I wish you were close by.  I could probably save you a few do-overs.  I had LOTS of em. LOL  It's the main thing keeping me from trying lots of different turbos.  Making headers and getting stuff to fit can get old after a while.

You're looking real good. WHat diameter of tubing are you using there?  Personally, if I do it again, I will use stock header pipes.  They are plenty large and made of good material and the ends already fit the head. LOL  You're past all that now though.  ;)
Fortis non Ferox
 Shafties Can't Wheelie

Offline turbo-max

  • Crotch Rocket
  • ****
  • Posts: 1766
  • AREA: Southeast Area
  • COG#: 10445
  • Membership Level: Active
Re: project build up
« Reply #48 on: October 26, 2012, 11:26:49 pm »
i'm not 100% sure of the original bike the pipes came from, but i'm sure it was a kawi of some sort, those where a pain in the a** as they where "double wall" pipes, so i had to cut and split the outter pipe off...today i purchased some nice small diameter stainless tubing to remake the header...i will post a pic of the materials later. ~jeff
turbo lag is a courteous head start!    ~Jeff H
99 c-10 "the purple monster"
01 c-10 undergoing turbofacation     
03 c-10 some mods...alot of miles
several other c-10's in pieces!

Offline Rev Ryder

  • Officer
  • I Need a Life
  • ****
  • Posts: 8742
  • We came. We saw. We Concours-ed.
    • Presbychuck
  • AREA: South Central Area
  • COG#: 7235
  • Membership Level: Executive Director
Re: project build up
« Reply #49 on: October 27, 2012, 12:14:42 am »
i'm not 100% sure of the original bike the pipes came from, but i'm sure it was a kawi of some sort, those where a pain in the a** as they where "double wall" pipes, so i had to cut and split the outter pipe off...today i purchased some nice small diameter stainless tubing to remake the header...i will post a pic of the materials later. ~jeff

Sounds like mine.  THey were originally 4 into 4 for an early Z1.
http://rides.webshots.com/photo/2360796110080494746RyjCiD
Fortis non Ferox
 Shafties Can't Wheelie