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Thread: A turbo project..

  1. #61

    Member #
    16449
    Bike(s)
    -99 1100xx
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    Jun 29 2013
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    sweden
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    Re: A turbo project..

    Quote Originally Posted by jersdunz View Post
    Any Updates?



    I'll do one tomorrow!

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  3. #62

    Member #
    14832
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    cbr 1100xxturbo
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    Re: A turbo project..

    these are my old pistons ! 79mm .
    the reason there abit lower is because i asked je to put more meat in the crown and make the dish abit dipper so if i remember right the cr was 9.2.1 .
    looking good ! i would balance the crank and get rid off the balancers too !but make sure you tap an allen head screw in the number 3 cylinder here is some of the magic i did latly cbrxx motor.jpgcbrxx motor 2.jpgcbrxxmotor 3.jpg
    drg180 and CanadianBird like this.
    turbocharged custom xx with 600rr fairings

  4. #63

    Member #
    16449
    Bike(s)
    -99 1100xx
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    Jun 29 2013
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    sweden
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    Re: A turbo project..

    I kept my balancers, it's a touring bike you know Just some extra hp.. That was a easy and smart mod to block the oil channels for the balancer shafts. Sorry for the non existing updates i'll try and do one as soon as possible. Ok than i know why the pistons look a bit different from my friends of the shelf Pistons. Have you had any problems with removing the original oil squirters that go through the original connecting rods? I guess they are not that effective anyways as they move and are not dedicated oil nozzles as stationary ones mounted in the engine block.

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  6. #64

    Member #
    14832
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    cbr 1100xxturbo
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    Re: A turbo project..

    carrillo doesnt have these holes , i guess there not needed as the goal to keep the pressure high in between the rod and crank .
    turbocharged custom xx with 600rr fairings

  7. #65

    Member #
    16449
    Bike(s)
    -99 1100xx
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    Re: A turbo project..

    Sorry it took such a long time!

    The engine got mounted in the frame a couple of weeks ago and i have been doing some small side-projects and waiting for some small parts. I decided to upgrade the turbo to a 19t instead so i ordered a Kinugawa compressor-house and compressor-wheel. I had to remove 1mm in radius on the chra to fit the larger exducer on the 19t wheel. A conversion wheel was a lot more expensive than this compressor-house and wheel together off Ebay.

    DSC_1220.JPG DSC_1168.JPGDSC_1234.JPG

    I also tried to remove all internal edges that disturb flow on all the piping and the intercooler. The turbo has a very nasty connection and when you mount a hose there will be a stage in diameter instead of a nice smooth transition so i made a cone in the lathe and welded it on too the compressor housing, the hose will go all the way down to the bottom so i don't weld it all the way around. adjusted the bellmouth to fit the larger inlet, its an adapter for the filter mostly to get some larger filter area.
    DSC_1237.JPGDSC_1233.JPG

    Officially a 19t!
    DSC_1239.JPG

    Started the bike a few weeks ago for a minute or so just to see that it works as i don't want to idle it just, better to just ride it normal to make the rings break in quickly. Rode it to the dyno at the motorcycle store for 18km where i occasionally work so i could do some mapping and check if everything seems ok from last year.

    I started off with some warming up and noticed a puddle of coolant under the bike and thought i could solve it with tightening some hose clamps as i could not locate the leak, this was not the issue.. Ended up being the o-ring between the thermostat housing and the cylinder head.. Off came the tank and the housing, the o-ring was perfectly flat and was almost as plastic. Was lucky and found an o-ring in a drawer that fitted (pretty lucky) Unhooked the wastegate arm and did some natural aspirated mapping and everything looked pretty good did some minor adjustments. Started to do some small pulls with boost and every time i hit boost it went very lean. Could not figure out the problem for a while so i continued with testing the extra map-sensor and found no faults. Tried again and it still went very lean. Suddenly i thought of the vacuum hose to the fuel pressure regulator and pulled in the small loop it makes on the side of the bike and.. Sometimes you just feel stupid

    DSC_1349.JPG

    So i hooked it back up and changed the original black plastic t-connection that doesn't have any surface for a hose to stick on to and now the boost compensation worked perfect again Ended up with a bit more horsepower than my goal that was 300.. The lambda curve also looked very nice and the oil looks as new after this dyno-session so i decided that i was done. No smoke from the exhaust so i guess the piston rings have settled properly. Very happy now

    DSC_1343.JPGDSC_1351.JPG

  8. #66

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    2343
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    2K Titanium, 85 V65 Sabre (Totalled but saved me)
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    Re: A turbo project..

    Your tempting me to pick your brain and build its twin over here
    drg180 likes this.
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.

  9. #67
    Supercharged Mod
    Member #
    4781
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    99 Bird standardish. 03 Supercharged KwakBird
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    Oct 25 2008
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    UK South West
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    Re: A turbo project..

    As usual some very nice work/thinking drg180.

    That O ring on the thermostat caused me some head scratching on my Daily Bird ..... water level dropping over a week but no puddles. I eventually saw some residue on the back of the block where the fluid had evaporated ....... my old O ring was in exactly the same condition.
    drg180 and Plexsica like this.
    Full of Hot air? Intercool yourself............ you know it makes sense

  10. #68

    Member #
    16449
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    -99 1100xx
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    Re: A turbo project..

    Not a single update in over a year, i suppose this means i should do one!

    This year i decided to leave the engine as it is and have a check after this season. I did check some valve clearences and remove the oil pan to check the residue that always ends up there. It looked pretty clean so i guess the engine is quite happy. However i wanted to rebuild some stuff that didn't work really as intended. I have had a wastegate-actuator located very close to the air filter, this worked pretty well with a foam filter but when i bought the KN-filter it got pretty pinched at the side and it was hard to remove when cleaning it.

    Since i bought the turbo i have been thinking of removing all the extra junk from the internal blow off-valve as it leaves big edges inside the turbo which probably help upset the flow.
    I milled off all the material from the internal bov and made som parts and welded them in place. Lots of grinding and sand-blasting later it ended up looking quite nice!

    Looks pretty ugly from the first solution i did.
    DSC_0584.JPG

    DSC_1239.JPGDSC_2326.JPGDSC_2329.JPG

    Finished result, also with the new actuator. Much better!
    DSC_2598.JPGDSC_2550.JPG

    My malpassi fuel pressure regulator was starting to leak some so i bought an Aeromotive from Summit.
    DSC_2581.JPG

    New returnline connection to the tank, kept the old one if i want to make it oem again.
    DSC_2535.JPGDSC_2537.JPGDSC_2538.JPG

    Made the returnline o-ringed instead of a paper gasket, at least it feels more proper
    DSC_2561.JPGDSC_2563.JPG

    New BOV, Turbosmart Veeport. Quality and finish is amazing but it was expensive..
    DSC_2614.JPG

    I also found some small leaks that i have fixed, now the bike actually builds boost earlier which is very nice, this means that all small tweaks actually does make a difference. A turbo in this boost range will have over-capacity so you will eventually reach the same boostlevel but it gets there quicker if nothing is leaking!


  11. #69

    Member #
    2605
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    '97 red....'bit pimpy innit'? according to my wife
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    Nov 11 2007
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    Bristol England
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    Re: A turbo project..

    This is all very impressive stuff. I've oftened wondered what a turbo'd 'bird would pull like, 'cause standard ones aren't especially slow really...I'm guessing incredibly well

  12. #70

    Member #
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    2K Titanium, 85 V65 Sabre (Totalled but saved me)
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    Re: A turbo project..

    drg
    Dogone it I am about the finish up the USD busa conversion. Wheels were going to be the last mod for my baby but as I said in an earlier post I may be sending a request for a build sheet, darn you grrrrr lol.
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.


 
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