Deano's GSXR turbo with f/inj update 20/10/11

[BANDITROD]

its sorter like using an oxy mate good luck with it all though;)

[Deano]

i am sure its easier said than done.

can mig, arc and oxy weld no probs so hopfully pick it up quickly.

[EXBEN]

Once you get up to speed on it the other welders will sit in the corner collecting dust (except when you need to whip up a workbench). Tig is by far the best. ;)

[Deano]

well the 7/12 is no longer as i got a 1100m frame and swinger from Jose.

swapped all the parts over and cut out the frame brace at the front of the frame were the centre 2 exhausts will run to the turbo inlet.

http://www.streetfighters.com.au/forum/upload/896163607263562.JPG

[Deano]

designed the look for the intercooler/oil cooler assy.

the cut outs on the side of the oil cooler will allow the no1 and no4 exhaust pipes to go around the cradle frame but also letting me have the cooler assy butted against the cradle down tubes.

http://www.streetfighters.com.au/forum/upload/89616360728965.jpg

[iopnr]

turbos are fun, when ther working right, hope to see more pics deano

[Deano]

http://www.streetfighters.com.au/forum/upload/615544992212463.JPG


got my laser cut parts back.
just got 1 of everything done in 3mm ally to see if they all fit before getting them cut in stainless.

there is a plenum end plate
exhaust boss clamp plate
turbo inlet and outlet flanges
and the emissions block off plate.

i have changed a couple of the designs of the inlet and outlet flanges but the ohers are fine.

am ment to get the`final parts`back on Monday.

i am getting enough cut to make 2 plenums and 2 exhaust manifolds if any one is intrested in the 2nd set let me no.

[Deano]

http://www.streetfighters.com.au/forum/upload/615544992197818.JPG
[8]

finally got all the bits for the seat unit i will be using

it is k4/k5 gix 600/750

no sure if the masking tape will be stong enough so i might get some ally an start making a subframe to suit it.

[Booster]

Deano what is the bolt spacing on the header flange ? and pipe size if its the same as i'm using on the busa i may get you to do a couple of more sets , was about to get some done but i need to do at least 3 at once to make it economical and i don't need full flangeplates at the moment.
Maybe even a turbo-header flange too.

[jose]

all looking good deano, can't wait to see the wheels turning :D

[Deano]

http://www.streetfighters.com.au/forum/upload/61554589145265.jpg


does this help mate.

if they are different it is no real drama to draw more in the size you require

[Deano]

http://www.streetfighters.com.au/forum/upload/514392329235945.JPG


http://www.streetfighters.com.au/forum/upload/514392329248397.JPG


got my laser cut parts back yestrday. enough to make 2 exhaust manifolds 2 plenums and 1 jig to bend the plenum body around

got alot of other stuff cut aswell like battery box for my fighter suframe parts guage mounts etc

also got a bosch fuel pump and ordered a malpassie rising rate reg, that should arrive in a couple of days

[BANDITROD]

that fuel pump big enough deano[:p] all your laser cut shit came up allright to mate i cant wait to see this thing in action:D

[Iceman]

That pump looks similar to the one I've got on the GS, I went for the fuelmisier though coz it was cheaper that the bosch.

[zx12argh]

If you dont mind me asking mate - how much did your laser cutting cost?

[latheboy]

Looks like you've got your arse into gear .. Gonna be a good'n
But look at all the laser cut bits i cant work out what the top left part is for ..
Dont worry just read it .. good work .. who's you laser cutter .. i use Rapid .. good fast cheap and no questions asked;)

[Deano]

ice, it is a bosch motorsport pump $130 and flow about 140(i think) ltrs per min

12 - got all the parts cut and material for $220. only alloy and stainless steel

rod - its smaller than it looks mate, bout the size of a coke can.

ivan - i use ABC laser cutting. they are good. delivery seemed to take alot longer this time as normal turnaround is 2-3 days but i keep haveing to ring them and hurry them up and the last 2 times i used them it was more like 2-3 weeks
the top left plates are going to be my jig for bending the radius on the plenum. i won't bore you with a detailed description so i will take a pic when i build it and post it up for you

[evad]

hey dean, where did you get the pump? ny idea on what current it draws when running?

[Deano]

quote:Originally posted by evad

hey dean, where did you get the pump? ny idea on what current it draws when running?



not sure on the current mate but got it from burson auto parts

[Deano]

made a bit more progress lately.

spent way to much time on the lathe making some bits like the exhaust bosses that had to be truned out of a big chunck of stainless steel. same goes with the plenum to throttle bodie inlets.

made the plenum jig. this will be what i bend the ally around to get the shape of the plenum to matcht the frame.

also got the mandrel bend for the exhaust manifold and mocked up the manifold. just gotta tack the collector and finish weld it.

http://www.streetfighters.com.au/forum/upload/8053407167627.JPG


http://www.streetfighters.com.au/forum/upload/8053407166179.JPG


http://www.streetfighters.com.au/forum/upload/8053407207550.JPG


http://www.streetfighters.com.au/forum/upload/8053407170254.JPG

[BANDITROD]

seems to be coming along nicely dean good job after you finish this will you be up to do it again

[Large]

tick tick tick tick....

[Deano]

quote:Originally posted by BANDITROD

seems to be coming along nicely dean good job after you finish this will you be up to do it again


probably mate, thats why i got enough material and laser cut parts to make 2 kits

[BANDITROD]

quote:Originally posted by Deano


quote:Originally posted by BANDITROD

seems to be coming along nicely dean good job after you finish this will you be up to do it again


probably mate, thats why i got enough material and laser cut parts to make 2 kits

fuck yeah thats the go mate

[evad]

Headers look good Dean, how are you coming with the TIG side of things? I think its like most welding? I guess like all welding the more you do the better you get :D
Project is coming along nicely!!

[Deano]

quote:Originally posted by evad

Headers look good Dean, how are you coming with the TIG side of things? I think its like most welding? I guess like all welding the more you do the better you get :D
Project is coming along nicely!!


ally is more challenging than s/s or steel but getting there mate.

you got your megasquirt running sprak yet?

[evad]

Hey Deano, yep its runnign spark, still got a few glitches but Im getting there slowly,lol

[Deano]

got the plenum welded up still gotta put the other end plate on and cut the up pipe inlets but will do that at a later date when i actually no where they are gunna go

http://www.streetfighters.com.au/forum/upload/1052400739205577.JPG

[Deano]

got the subframe nearly completed just a few minor touches to go.

settled on a seat angle and height to match the watercooled tank

http://www.streetfighters.com.au/forum/upload/891347631266940.JPG

[Deano]

http://www.streetfighters.com.au/forum/upload/891347631262861.JPG


just about finished the headers. just gotta grind a couple of welds to neaten them up and they are set to go.

got the output flanges waterjet cut out of 12mm stainless.

next is to complete the exhaust system

[BANDITROD]

lookin good deano when are you hoping to get it running[?]

[ozkat]

Are you going to use a scavenge pump to return oil back to the sump? That turbo looks really low.

[Deano]

not sure when it will be running. it all depends on the cash

will be using a scavange pump of some sorts but havn't obtained one yet.

[Fish]

Deano that is some very neat work there, I'll be stealing your ideas later for mine. :D

[latheboy]

Thats looking great Deano well done .. Are you going to support the turbo just on the pipes ? And have you CCed each pipe to get them the same and how much volume did the plenum turn out to be ..

[Diebythereaper]

Am new so just read this thread from the start. WELL DONE!
Fantastice project, saw your pic posted on OSS.
ALot of effort gone in and very interested to see how this is going to turn out. im not a turbo expert so bits I dont fully follow but am interested in fuel injecting my gsxr.

Keep it up lad!!

[Seifer]

Yeeah Deano, very keen on on the EFI myself. How hard were they to fit, was it a matter of a stretching the injectors to fit over the carbs or alot more to it. Also what other components do you need to make it run ie ECU etc?

[Fish]

Yeah what they said:D

[Seifer]

I imagine ur also going to need a decent fuel pump, oxygen, exhaust sensors etc...

[Gix11]

Where's the EFI maestro when you need him? Evad???

http://www.streetfighters.com.au/forum/upload/52288544787439.jpg

[Seifer]

What are we looking at there Gix?

[Gix11]

Dave's fuel injected '79 Z650. (Admittedly, that isn't a very good shot of the set up - it's all I could find and is hidden behind the head). What Dave doesn't know about Fuel injection conversions doesn't seem worth knowing.

[evad]

Yeah where is the EFI maestro? I think you got the wrong bloke Si!! [:0]
My zed is injected using a DIY megasquirt ecu and the hardware from a gpz1100 kawasaki. I have a a lot of help from other msefi.com forum members and made some good mates as well. Must say if I can get it to work anyone can, I think that a wide band o2 setup is essemtial for tuning unless you can afford to get it set up on a dyno.

[Booster]

For what a dyno session can cost i prefer to buy the wideband O2 with logging and can re adjust anytime i change things.

[Deano]

turbo will be surported only off the pipes. i am expecting to have to make another manifold in time but we will see how it goes.

unsure on exact plenum volume but expect 2lt. zorst is not equal length. was unable to do that and keep within the design parameters.

have a bosch fuel pump that flows about 140 or so lts per min.

the throttle bodies are a prick to get in the bandit rubbers but they will fit. found it easier to get some 40mm pvc pipe from bunnings and cut 4 peices and put those in tbe rubbers to strech them a bit and then put the tbs in.

still have heaps of bits to buy as far as the fi is concerned so will update you guys as i go, don't worry you havn't missed out on anything.

[latheboy]

Hey Deano .. will that plenum fit my bike with carbies ??? if yes how many did you make ??

[Deano]

ivan

it wont as such mostly cause the spacings are all equat and not wider in the centre. piece of piss to do another one for you mate. will do a few things differently next time but if you need info or drawings etc let me no. even after building this one i would never do it the same again as i worked out a better way of building it

[Fish]

Hey deano, how's it coming along? got that inj sorted yet?

[Deano]

not yet mate.

haven't done anything with the exhaust yet but have been working on the subframe for the new seat unit.

still got to weld up a couple of things (ran out of gas) and then weld the tabs to the frame, make the tank mounts and i am set to go.

i got some 54mm rad hose yestrday so that i can fit the plenum to the throttle bodies, this will enable me to start fabricating the up pipe.

will get some pics later

[Deano]

made a little progress lately.

got some 54mm rad hose for the couplings from plenum to throttle body.

this ment i was able to fit the plenum to the throttle bodies and sort out the up pipe inlets to the plenum.

very happy with the overall fit and shape of the plenum, seems to match the frame shape well

http://www.streetfighters.com.au/forum/upload/930147381245874.JPG

[Deano]

spent a bit of time on the lathe and knocked up the adaptor for the turbo. it will fit 2" silicone hose and hopefully the silicone hose will go straight into the intercooler.

http://www.streetfighters.com.au/forum/upload/930147381218718.JPG

[Deano]

got the tabs made for the seat unit.

just gotta weld them into position.

also have just about finished the subframe. just have to make the fuel tank mounts and then late down the track i will have to think about things like the battery box and computor mounts etc

http://www.streetfighters.com.au/forum/upload/930147381208944.JPG

[Iceman]

Look'n good Deano. Top stuff.

[Deano]

once the plenum was fitted i was able to see how the up pipe would fit to the plenum.

i will be using the 1-1/2 alloy tube shown in the pic. there will be 2 pu pipes, one between 1-2 and the onther between 3-4

http://www.streetfighters.com.au/forum/upload/93014756947732.JPG

[rod185651]

I am only new here, but have to say very impressed on what you have done so far. Nice.. very nice.

[xb9r]

that is some tidy craftmanship there yoda

[BANDITROD]

lookin good deano keep up the good work

[Deano]

spent most of today watching the cricket and finishing the plenum.

just needs a polish and be presurized to check for leaks and its done.

not my best welding with the up pipe spigots but good enough for what i want.

http://www.streetfighters.com.au/forum/upload/65335893214959.JPG

[Deano]

and another pic from the right side. i welded on the end plate once i finished the up pipe spigots as i still wanted to be able to get my hand inside the plenum to clean out any filings.

http://www.streetfighters.com.au/forum/upload/65335893204257.JPG

[Pab13]

Fuck Deano your the man some nice work there good watching the build your
nearly there mate keep up the good work.

[BOHEMION]

Been looking at ALOT of examples of turbo installs and yours is the cleanest by far! Awesome stuff.

[Jockney Rebel]

nice one deano very professional..ur not bad at stickin bits of metal together are ya ?

[Deano]

thanks guys. welded on the top seat unit tabs last night. will hopefully get the bottom tabs welded tonight.
don't worry boh. still got plenty of time to fuck it right up yet

[latheboy]

Thats ghey deano .. get some real skills and get a life ..
;)... Awesome work there buddy .. i should over for a visit one day and talk shit while looking at cool stuff..
Werd

[zx12argh]

Coming along very nicely mate - going to be ready for afr? ;)

[Deano]

ivan

i could be gheyer mate, i could be trying to turbo a 750 - werd - welcome anytime mate

doubt it will be ready for afr. don't no if i will be going yet anyway.

time will tell

[Gix11]

quote:Originally posted by Deano

don't no if i will be going yet anyway.


Hey! What's this pants?

[sharky]

AFR t-shirt for mexicans.....................













http://www.streetfighters.com.au/forum/upload/27428576011881.jpg

[Gix11]

Darren would look good in that.

[TurboKat]

I'm getting Damo one.

[Fish]

VERY fuckin noice Deano. so are you selling the plenums too? I'll take five!:D

[fimpBIKES]

and thats why he's the 2006 ASF Fools Run Multi Award Winner

[Deano]

quote:Originally posted by Bitchfish

VERY fuckin noice Deano. so are you selling the plenums too? I'll take five!:D


everything is for sale at a price;)

[Fish]

will it fit with a bandit frame and how much overtime do i need to do? I'm looking for some cheap K1 throttle bodies on fleabay for it too. :D Maybe I'll just ask when I HAVE the money.

[Deano]

unssure if it will fit the bandit frame but if need be i can measure it all up and you can check it out.

are you thinking for turbo or n/a use

[Gsxar]

Wicked Deano:D:DSee this is why we now EXPECT such high quality stuff from you:DIf your going to do it you do it well;)

[Fish]

quote:Originally posted by Deano

unssure if it will fit the bandit frame but if need be i can measure it all up and you can check it out.

are you thinking for turbo or n/a use

start n/a but turbo when i can afford one. spose thats a pain in the ass. I may just hoard the parts and do it all in one hit. what do you reckon?

[Deano]

i plan to get this running with n/a fuel only once i get my head around tuning fuel i want to swap over to spark aswell. once i have that sorted i will add boost.

less chance of fucking up a good engine

[Fish]

yeah that's what I was sort of planning. building up a good n/a motor and then adding boost after it's already making good power. start with a nice low boost and build it up after a while. can afford to put new motors in every 2 minutes.:(

[Deano]

finially got around to finishing off the cables. had to make little sleeves to join the TL cables to after market outer cable.

http://www.streetfighters.com.au/forum/upload/77316156229994.JPG

[Deano]

more or less this is the plan for the up pipes. got some 1-1/2 45deg stainless bends the other day. had to cut a little out of the tank to make them clear. just got to make then join up behind the headstock and should be a gooden

http://www.streetfighters.com.au/forum/upload/77316156245873.JPG

[Deano]

had these spondon clip ons that i was goin to use on the track bike but they didn't fit. put them on upside down and back to front and i think they will be great. pushed then a fair way forward aswell so they are nearly straigh across.

http://www.streetfighters.com.au/forum/upload/77316156238392.JPG

[latheboy]

Good work Deano .. Are you going to heat wrap those inlet pipes .. wouldnt want the melting the throttle cables

[Deano]

hadn't thoutght of that mate but am hoping that they wouldn't get hot enough to melt anything.

[latheboy]

It shouldnt happen but i have seen it on a twin turbo big block and it not pretty when the throttle stay's wide open...
Nice welds by the way.. I might have to get some time at work for you when you get it running;):D

[BANDITROD]

fuck this is gunna be awsome deano i cant wait to see it in action mate

[Deano]

working on booster's rule of thumb that every 15psi will give approx 100deg increase in intake air temp i should be right.

mate if you happen to have a dyno that needs 'running in' and i happen to have a turbo bike that needs tuning then it sounds like a match made in heaven

[pappas]

FUCKING AWESOME!!

Keep up the good work!!:)

[Deano]

http://www.streetfighters.com.au/forum/upload/73712560470473.JPG


progress on the bike has been slow lately but managed to get the dump pipe completed this arvo

[Jockney Rebel]

very nice work there deano mate but then i wouldnt expect anything less from a bulider of ur calibre [btw wheres me cheque ]lol

[Deano]

cheers mate
you mean you havent got the cheque yet, i swear i sent it oh well there is always next time

[Deano]

http://www.streetfighters.com.au/forum/upload/814870164252777.JPG


got my muffler finished today. made the muffler out of a bit of 3" stainless tube with 2" perf tube up the guts.

took awhile and not that happy with the 2 joins half way up the 2" pipe but it will be good enough for me.

[latheboy]

Looking good deano .. So how long till it makes brumm brumm noise's?

[Deano]

quote:Originally posted by latheboy

Looking good deano .. So how long till it makes brumm brumm noise's?


i would love to say not long but you no what these projects are like.

but here is a little 'to do list'

up pipe fab
intercooler (or no intercooler need to make a decsion)
computor
get computor to work (ignition drivers, sensors and innition pick up)
fit inlet air temp sensor, map sensor, coolant sensor and af sensor
buy wide band af gauge
mount gauges
buy and mount headlights.
make battery box
buy/make catch tank
sort out oil return for turbo
oil feed hose to turbo
put new seals in front forks
finish off the subframe
mount fuel pump and filter
weld in new bottom in fuel tank
make bung for fuel to go to pump and weld to tank
buy oil cooler and lines and then mount them
buy seat lock
wiring
route fuel hoses
sorce and fit boost gauge
test waste gate and make new push rod and mount.
make hanger bracket for new muffler
fit window clutch cover
source a K, L, M clutch basket then fit slabby coil spring clutch
fit manual cam chain tensioner
sort out a new smaller front brake res
sort out blinkers

and then i have all the cosmetic stuff like powder coating and painting.

after that i gotta tune the thing and to do that i got to learn the software for the computor that i end up using.

after that i will probably ride it a couple of times scare the shit out of myself and park it in the shed vowing never to ride it again (hope not though)

but you wished you never asked ivan (i wished you never asked, that is a long list)

[latheboy]

BAhahahahaa but thats only about a weeks work for a guy like you ..

[pappas]

Thought this might help you out, is cheaper than Jaycar unit.
DSE
http://www.dse.com.au/cgi-bin/dse.storefront/47f30067009ffcfa2740c0a87f9c070b/Product/View/K4213
Jaycar
http://www.jaycar.com.au/productView.asp?ID=KC5300&CATID=&keywords=fuel+mixture&SPECIAL=&form=KEYWORD&ProdCodeOnly=&Keyword1=&Keyword2=&pageNumber=&priceMin=&priceMax=&SUBCATID=

You've prob already seen this but hey what else am i gonna do at work?!?!?!

[Booster]

Interesting comparo on widebands here http://www.innovatemotorsports.com/resources/FM_WB_Shootout.pdf

[Deano]

that was an intresting read. was planning to use a tech edge unit. need the logging ability and for it to talk to the ecu for closed loop running

[BANDITROD]

waiting in anticipation deano that pipe looks fucking sweet mate

[fimpBIKES]

quote:Originally posted by Deano
got my muffler finished today. made the muffler out of a bit of 3" stainless tube with 2" perf tube up the guts.

took awhile and not that happy with the 2 joins half way up the 2" pipe but it will be good enough for me.


looks fine to me!
hangs off the turbo yeah, be fine

can you just not run an intercooler and see what happens?