A turbo project..
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Thread: A turbo project..

  1. #1

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    16449
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    A turbo project..

    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
    IMAG2335.jpgIMAG2351.jpgIMAG2362.jpg

    Had to build a holder first to see how close to the front wheel the radiator would end up
    IMAG2365.jpgIMAG2379.jpg

    First pipe spot welded so i could build a jigg to replicate the same location between the connecting stud pipes and the turbo flange.
    IMAG2386.jpgIMAG2388.jpgIMAG2402.jpgIMAG2405.jpgIMAG2408.jpgIMAG2411.jpgIMAG2413.jpg

    Cutting each runner one at a time and than i matched them at the flange
    IMAG2432.jpgIMAG2433.jpgIMAG2434.jpgIMAG2437.jpgIMAG2453.jpgIMAG2458.jpgIMAG2460.jpg

    A bit nerv wrecking to see if they fit but they did
    IMAG2462.jpgIMAG2464.jpgIMAG2474.jpg

    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..
    IMAG2497.jpgIMAG2494.jpgIMAG2518.jpgIMAG2515.jpgIMAG2521.jpgIMAG2523.jpg

    The shiny result after some chemical cleaning and polishing
    IMAG2538.jpgIMAG2540.jpgIMAG2527.jpg

    My very tiny but full of things garage
    IMAG2475.jpg

    The only bolt on part i have found yet is the fuel pump..
    IMAG2469.jpg

    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.
    IMAG2502.jpgIMAG2504.jpgIMAG2505.jpg

    One successful and one failed part for connecting the oil feed line to the turbo
    IMAG2507.jpg

    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.
    IMAG2511.jpgIMAG2556.jpgIMAG2557.jpgIMAG2560.jpgIMAG2566.jpgIMAG2573.jpg

    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"
    IMAG2576.jpgIMAG2580.jpgIMAG2583.jpgIMAG2584.jpgIMAG2591.jpgIMAG2598.jpgIMAG2599.jpgDSC_0006.JPG


    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..
    DSC_0007.JPGDSC_0010.JPG

    The cams are asjusted to 105 degreed lobe center on the intake cam and 106 on the exhaust cam.
    DSC_0014.JPGDSC_0016.JPGDSC_0017.JPGDSC_0019.JPG

    Building a mount for the wastegate
    DSC_0034.JPGDSC_0037.JPGDSC_0039.JPG

    Time for the engine to get back in to the frame
    DSC_0042.JPGDSC_0045.JPG

    Building a downpipe, will use 3" all the way and a 3" muffler.
    DSC_0063.JPGDSC_0069.JPG

    Fuel pressure regulator and a mount for it
    DSC_0078.JPGDSC_0080.JPGDSC_0081.JPG

    Thats were the blow off valve sits
    DSC_0083.JPG

    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
    DSC_0084.JPGDSC_0085.JPGDSC_0087.JPGDSC_0089.JPGDSC_0093.JPGDSC_0094.JPGDSC_0102.JPGDSC_0103.JPGDSC_0105.JPGDSC_0106.JPGDSC_0110.JPGDSC_0112.JPGDSC_0116.JPG

    Will continue to update as the build goes on, my goal is to start it before January ends

    Pictures at the end, how do i remove them? Guess they are bonus pictures..
    Attached Images Attached Images

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  3. #2
    bladebird
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    Re: A turbo project..

    hi some very clever stuff going on there gd luck

  4. #3

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    Re: A turbo project..

    Lots of work and thinking. Nice job, waiting to see it done. One question, I thought that Honda valves were harden face and couldn't be ground without taking the hardness off. Really don't know. The valves look like any other from your pics.

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  6. #4
    Super Moderator
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    Re: A turbo project..

    looking good

  7. #5

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    Re: A turbo project..

    Thanks guys! I try to do my best

    Quote Originally Posted by RollinOn View Post
    Lots of work and thinking. Nice job, waiting to see it done. One question, I thought that Honda valves were harden face and couldn't be ground without taking the hardness off. Really don't know. The valves look like any other from your pics.
    I know it does say so in the manual and I asked the guy who did the job and he said it depends on how deep you grind as the surface hardening goes to some depth. I could not afford 16 new valves but i would have gone that way otherwise. I think i will have an eye on the valve clearance to see if they start to wear down again than i'll go for a second hand low milage head instead

  8. #6

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    Re: A turbo project..

    Well done.And I think you posted more pics than anyone ever has in one post.
    drg180 likes this.
    9.5's or better,this better be the year.

  9. #7
    Supercharged Mod
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    Re: A turbo project..

    A truly excellent build there drg180 ............ why were projects not like that when I did my Mechanical Engineering degree!

    One point (which I suspect you have already covered) concerns the intercooler positioning. When building my supercharged Bird there was potential for a clash between the mudguard (fender) and the bottom of the intercooler when the suspension was on full compression. Now this may be due to the USD ZX12R forks that I use but I ended up removing a section at the bottom of the intercooler to add clearance.

    The only reason why I'm raising this is because the clearance on one of your photos looked 'tight'.

    I really enjoy these 'engineering build' threads, please keep the info flowing, sounds like January could be a big month!
    Full of Hot air? Intercool yourself............ you know it makes sense

  10. #8

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    Re: A turbo project..

    Well done, Im looking forward to follow this. I would also like to see a link to the Swedish forum.

  11. #9

    Member #
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    Re: A turbo project..

    I should of course have pointed out that on the picture with the fender touching the intercooler the fork is lowered in the fork crowns to be matching a bottomed out fork. So it will just touch when bottoming hard, if you look at another picture there is plenty more clearance. Had to remove one cell already from the intercooler when i started measuring and welding it together. I might shorten the travel of the fork at the end or just buy progressive fork springs but thats a easy to solve later problem

    Swedish thread is: Intense's Blackbird turboprojekt
    TheDuck likes this.

  12. #10

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    Re: A turbo project..

    And Hovstasx, i did read your thread a couple of times before i started building and i am mighty impressed with your build and all the parts you have made! Hej förresten

  13. #11
    The Gimp
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    Re: A turbo project..

    Let us know how the radiator does... For the sake of simplicity, I'd like to mount mine similarly, but I'm not sure it could handle an Alabama summer.

  14. #12

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    Re: A turbo project..

    It is pretty boring to wait for parts during Christmas holidays.. I am still waiting for a oil cooler and i need to buy a Power commander 5 and re solder some of the wires to fit a Blackbird (yes you can). Also i am going to buy a WideBand Commander and the pod300 display so i can log whatever i like to. I do have some other stuff to complete though and have spent some time in my garage during the holidays.

    I decided that i need a extra mount for the intercooler to hold it still.
    DSC_0130.JPGDSC_0133.JPG

    Cut some hoses and short pipes for the route between the intercooler and the plenum, ended up looking quite nice. Its a bit tight on full lock to the right but honestly you don't use full lock when riding, probably only when stopping and turning the bike around with your feet down..
    DSC_0124.JPGDSC_0126.JPG

    Tetris
    DSC_0118.JPG

    Found a large Uni airfilter in a shelf and thought it could use an adaptor between the turbo and it. Just have to put it in the lathe and make it fit..
    DSC_0134.JPGDSC_0135.JPGDSC_0136.JPG

  15. #13

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    Re: A turbo project..

    Awesome thread with great pictures, waiting to see the running final end result and numbers. Keep at it! Keep the info coming. Sure wish I was capable to do this.Perhaps if I had no job and could start a second career
    drg180 likes this.

  16. #14

    Member #
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    Re: A turbo project..

    More building and welding!

    Had to make and weld a bracket for the front oil cooler as my upper bracket did not have this and i didn't want to buy one from a 97-98 Blackbird
    DSC_0149.JPGDSC_0150.JPG

    Had to weld two mounts for the ignition coils, i try to not make any ziptie solutions as they tend to end up standing at the side of the road
    DSC_0154.JPGDSC_0167.JPG

    I hate when this happens..
    DSC_0153.JPG

    Had to cut a bit in the side panel and if anyone asks i'll just tell them it's a very thick cooling hose!
    DSC_0156.JPGDSC_0157.JPG

    Cutting a hole in the side fairing for the air filter, have started to assemble things properly for a start up in a couple of weeks. Not a very discrete solution but i think it looks quite cool anyways..
    DSC_0161.JPGDSC_0163.JPG

    Selfies are very popular these days but i find it a lot cooler with a weldfie!
    DSC_0143.JPG

    Over and out!
    xxx99 likes this.

  17. #15
    Supercharged Mod
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    Re: A turbo project..

    Spot on with the coil mounts, mine are similarly mounted ....

    3.JPG
    drg180 likes this.
    Full of Hot air? Intercool yourself............ you know it makes sense


 
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