I wrote some questions before in other threads about turbo and i though i could share my build from a Swedish forum as i try to take lots of photos for documentation and so on. I am currently trying to finish my master in mechanical engineering in combustion engines here in Stockholm, Sweden so i happen to have access to mills, lathes and a water cutter and thought i should build this while i can, or else i might have to buy my own equipment
However i am not done yet but i am getting close to being able to start the bike, as this is from a ongoing thread on a Swedish forum i'll just leave some shorter comments around the pictures.
Flanges and pipes in stainless steel
Had to build a holder first to see how close to the front wheel the radiator would end up
First pipe spot welded so i could build a jigg to replicate the same location between the connecting stud pipes and the turbo flange.
Cutting each runner one at a time and than i matched them at the flange
A bit nerv wrecking to see if they fit but they did
A ghetto pre-heat before welding on my small heater, left a friend who has worked as a welder to do the narrow and hard to reach parts..
The shiny result after some chemical cleaning and polishing
My very tiny but full of things garage
The only bolt on part i have found yet is the fuel pump..
Had to make an adaptor to be able to connect the hose to the end of the fuel rail as the original fuel pressure regulator sits directly on the fuel rail.
One successful and one failed part for connecting the oil feed line to the turbo
Time to build some plenum chamber, bought a half completed part that i found in another thread here. It was a turbo kit not really complete for a 1100xx but the plenum was very pooly made so i should have done it from scratch but with some rebuilding it ended up lookng quite good. Had to make the funnels inside also.
Time for some attention at the engine, i started with checking the valve clearances and on one cylinder there was almost no clearance at all so i suspected the valves or valves seats to be a bit knackered and it ended up being the valves.. reground and mira-cut valves seats and were "back on track"
The compression is lowered to around 9:1 with 3 head gaskets stacked and i use loctite 3020 for some extra sealing and overtighten the head studs just a tad bit..
The cams are asjusted to 105 degreed lobe center on the intake cam and 106 on the exhaust cam.
Building a mount for the wastegate
Time for the engine to get back in to the frame
Building a downpipe, will use 3" all the way and a 3" muffler.
Fuel pressure regulator and a mount for it
Thats were the blow off valve sits
Time to build a intercooler and make it fit in front of the radiator. The radiator is off a 97 1100xx and the intercooler is bought as a build kit from mc-xpress. The fans are from a R1 07-08
Will continue to update as the build goes on, my goal is to start it before January ends :hmm:
Pictures at the end, how do i remove them? Guess they are bonus pictures..
However i am not done yet but i am getting close to being able to start the bike, as this is from a ongoing thread on a Swedish forum i'll just leave some shorter comments around the pictures.
Flanges and pipes in stainless steel
Had to build a holder first to see how close to the front wheel the radiator would end up
First pipe spot welded so i could build a jigg to replicate the same location between the connecting stud pipes and the turbo flange.
Cutting each runner one at a time and than i matched them at the flange
A bit nerv wrecking to see if they fit but they did
A ghetto pre-heat before welding on my small heater, left a friend who has worked as a welder to do the narrow and hard to reach parts..
The shiny result after some chemical cleaning and polishing
My very tiny but full of things garage
The only bolt on part i have found yet is the fuel pump..
Had to make an adaptor to be able to connect the hose to the end of the fuel rail as the original fuel pressure regulator sits directly on the fuel rail.
One successful and one failed part for connecting the oil feed line to the turbo
Time to build some plenum chamber, bought a half completed part that i found in another thread here. It was a turbo kit not really complete for a 1100xx but the plenum was very pooly made so i should have done it from scratch but with some rebuilding it ended up lookng quite good. Had to make the funnels inside also.
Time for some attention at the engine, i started with checking the valve clearances and on one cylinder there was almost no clearance at all so i suspected the valves or valves seats to be a bit knackered and it ended up being the valves.. reground and mira-cut valves seats and were "back on track"
The compression is lowered to around 9:1 with 3 head gaskets stacked and i use loctite 3020 for some extra sealing and overtighten the head studs just a tad bit..
The cams are asjusted to 105 degreed lobe center on the intake cam and 106 on the exhaust cam.
Building a mount for the wastegate
Time for the engine to get back in to the frame
Building a downpipe, will use 3" all the way and a 3" muffler.
Fuel pressure regulator and a mount for it
Thats were the blow off valve sits
Time to build a intercooler and make it fit in front of the radiator. The radiator is off a 97 1100xx and the intercooler is bought as a build kit from mc-xpress. The fans are from a R1 07-08
Will continue to update as the build goes on, my goal is to start it before January ends :hmm:
Pictures at the end, how do i remove them? Guess they are bonus pictures..