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

[Deano]

i was thinking about that mate. the other thing is that if i got to all the troble of building an intercooler and it turns out i the compressor is not big enough i may have to change it, if tbe new compressor stays the same deminsions as the old one then the intercooler will still fit but if it changes then my new flash intercooler may not fit the new compressor housing.

i may just run with out and keep an eye on inlet air temps. i asked the question on OSS about inlet air temp and a couple a guy that is running efi and turbo is getting abot a 10-15deg rise at 6psi boost on a 30deg day. that i can deal with. i want to put on an intercooler but i would like to no what the turbo will be like first as i don't like to do things twice.

we will see what happens.

wont be doing anything to the bike for hte next week or so as the track bike as been brought up the prioty list.

team ASF goes racing at phillip island next saturday so have a few jobs to do on that to get it ready for battle

[DaveK5]

Have ya thought about water injection Deano ?

[Deano]

i have mate but that would be a last resort. prefer an intercooler

[Deano]

http://www.streetfighters.com.au/forum/upload/1052687468240211.JPG


got the last of the bits from ebay to do the coil spring clutch conversion. just gotta make a couple of spacers up and then get a lock up clutch fitted.

[Deano]

http://www.streetfighters.com.au/forum/upload/1052687468245420.JPG


brourght myself one of those cheap coolers of ebay. going to put it under the seat with a davis craig thermo fan keeping things cool.

tight fit but should work. the thermo will be run by the ecu.

[BANDITROD]

awsome work mate love it keep the pics coming [:p]:D

[xb9r]

Will you modify rear cowl to assist air flow e.g some sort of ducting or speed holes ?

[Weaselman]

Like a Benelli Tornado

[HueyonaBlade]

Nice little bit of ingenuity there Deanno

[Deano]

cheers guys

at this stage the rear cowl will stay untouched. the fan should be able to draw air easy enough but i am prepared to put some grilles in it if it needs it.

[Fight_fan]

Fuck deano! Thats unreal! I really need to go n learn how to weld properly!

[evad]

very nice Deano, definatly thinking outside the square on this one!!

[latheboy]

Thats a good idea but will you have enough clearance for the fittings on the cooler?

[fimpBIKES]

good shit, gonna wire the fan up to blow rather than suck?

imagine there would be negative pressure under the tail anyways

very sneaky!!!

[Deano]

ivan- i will have to chop up my subframe to fit in the fittings. the cooler is just sitting in there for the pic.

fimp - the fan will be blowing, i thourght about having it suck but then i will have a tail unit full of dust and shit that will get sucked into it.

[Deano]

after been to lazy to post up progress pics i thourght i had better get around to showing you girls what i have been up to.

no with the 7/11 gone to figtfan i have some inspiration to get this project back on track

i have been spending alot of time lately on this and have made some great progress. the subframe assy and undertail are 90% done. the oil cooler is rubber mounted and ready to accept fittings. the thermo fan is fitted onto the subframe and that is ready for wiring.

the undertray is mostly finished. i can't finish that completely until i get my computor and ingnition modules to see where everything will fit, the battery holder is done.

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288481399.JPG


got myself a turbosmart type 1 blow of vale. $20 from ebay, couldn't let that go

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288257895.JPG


after seeing what ben did with the judge and pete's busa i thourgh the top of the tank would be a great spot for the boost gauge, if i knew how fucking difficult it would be to weld then i would have thourght twice.

got an autometre liquad filled gauge from the states new for $90

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288218352.JPG


made my undertray. started with some carbord from officeworks and made a template then transfered it to the ally. not as hard as what i was expecting

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288204984.JPG

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288217464.JPG


welded a window clutch cover, lucky i no a guy that can supply them cheap:D

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288234143.JPG


tail with solo seat cap lock done aswell as the thermo and cooler in final position.

its a bloody tight fit

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288280276.JPG


got the intercooler core and welded on the top tank

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288382495.JPG


got a tial wastegate form the states

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288454988.JPG


with the intercooler in position the up pipes should fit nicely

[Deano]

http://www.streetfighters.com.au/forum/upload/728822288257997.JPG


with the intercooler held in position with a ratchet tie down i can now work out my bottom tank

[evad]

That looks great Deano, shes going to be really trick omce your done :D Your welding on the intercooler tank look great aswell, quite the pro welder hey!!!!

[latheboy]

Are you going to have enough clearance for the front wheel to travel through its full stroke? .... I have never welded a tank before, throught about it a few times, but a mate of mine did one earlier this year and he had heaps of trouble with it .. it was a hardly tank so its crap already .. Did you fill it with exhaust fumes or just go for it?
Looking at the way your going she'll be ready for the GP this year ..;):D

[BANDITROD]

lookin good mate cant wait to see more :D

[Booster]

I have had no problem welding tanks but most times filled with water, last one was too much welding and holes to put water in so i put a vacuum cleaner suction in and turned it on.

If your tank welding is anything like the intercooler Deano you will have no problem :)

[Gix11]

Bloody nice work mate and top effort with the photos. Cheers for that.

[Deano]

the biggest problem i had was the tank was so thin and the tube that the gauge goes in was alot thicker. i needed to use more amps to weld the thick tube but if i wasnt careful i would just melt the thinner tank away in a flash.

the tank had been sitting for ages with no fuel cap and a hug hole in the bottom so i didnt worry about the fumes. they were long gone.

evad - the outside corners are the easiest welds to do. i will do things a little differently on the next intercooler i make so it will be even better.

ivan. i will double check the clearance but i hope it will clear no worries.

[Deano]

the bike may be built by the gp but i hardly think it will be a going concern. it is all the little things that will take the time.

[Iceman]

Look's great Deano, you've almost inspired me to get off my fat arse and get back into the shed to finish off the GS............. almost.

Great work mate.

[Gsxar]

You do it all so well Deano, top effort, your a talented boy;):D

[Deano]

checked the clearance and it will be tight but hopefully it will be fine.

do worry Jo it is all just smoke, mirrors and good luck so far

[Deano]

quote:Originally posted by Iceman

Look's great Deano, you've almost inspired me to get off my fat arse and get back into the shed to finish off the GS............. almost.

Great work mate.




go on i dare ya

[Fight_fan]

Nice work Deano! Its lookin unreal mate!

[Razorback]

FREAK OUT! Engineering masterpiece Deano cant wait to see more

[MotoMax]

Hi Deano, Thought I would give you advice from experience regarding clearence between Turbo and front wheel. With the fork tops off ie the front fork at full compression, you will need at least half inch clearence to allow for tyre growth at speed and fork deflection under hard braking. On mine, I can get my finger between intercooler and tyre on full travel and there is still signs of touching. Also dont forget the turbo will move at least 5mm under expansion of header pipes when red hot or white hot or translucent depending on how hard you run it! :D

http://www.streetfighters.com.au/forum/upload/93773811933409.jpg

[Deano]

at the moment i have the gaurd rubbing on the intercooler with the forks slide through the bottom triple 120mm. this dosn't allow for flex in the forks.

also i am led believe the bottom 20mm or so of fork trave is unusable anyway so i should be right. i plan to cut the back of the guard away anyway so that will give me another 1/2 inch or so.

[MotoMax]

There are lots of things you can do, like dropping the forks through the yokes or making a dogleg top yoke to drop them further, but that will change your rake. As a rule of thumb every 25mm of ridehieght changes the rake angle by 1 degree which will effect the handling. You can even offset the forks forward with different yokes but that to will effect the trail and thus the steering geometry.
You can restrict the travel in the fork internally with spacers or even put a stronger fork spring in there so you dont use the full travel, but that to will effect the handling and is not what you want. It is true that some forks hydraulic towards the bottom of the travel, but dont count on that.
Its best if you give yourself plenty of clearence to start with.
I know everything is a compromise, but thinking about the job a bit and getting it right will make your bike stand out from the rest.
Fucking good job so far though, I am impressed with the use of SolidWorks.....Streetfighters in the 21st Century fucking marvalous!

[Deano]

one thing i definetly don't want to do is compromise the handeling. this bike will see some track time at phillip island so good handeling is a must. i will be getting the front and rear suspension redone to suit my weight and intended riding.

if i bring the intercooler in tighter i will then only have a few mm to the headers and i would prefer a bit more clearance than that.

[MotoMax]

If you want it to perform on the circuit then you will need to use all the fork travel you have and even be prepared to drop the forks through the yokes which will give you even less wheel to intercooler clearence.
What I did was re-mount the standard rad as close to the engine as possible, in fact the bottom of my rad touches the headers which isn't a problem because there is no chamber on the bottom run. The other thing you can do is distort the core in the centre, as that is the only place there is a clearence issue, this can be done quite easily on a press with a curved former, you will be amazed how much you can get away with. If you look at my intercooler above, that started life as a straight core, the curvature was put in it on a fly press.
Good luck :)

[Deano]

i dont really plan to drop the forks through, my race bike has extreme geometery and works great but i would plan to take it out for a few laps when i go to a track day and then swap bikes back again after a couple of laps.

i already have gone to far down the straight intercooler track so i will persue that but i might have to finish the second set of headers that will allow the intercooler to be mounted back against the motor slightly. i notice that your installation dosn't require your outer 2 zorst pipes to be routed around a frame down tube, this dictates a fair bit the position of the headers and intercooler.

[MotoMax]

there are a few ways to skin a cat, it all depends on how you think about it, your problem is the frame rails, mine was the limited space created by a short stroke motor.
I used micron serpent header bends to give me more clearence. Did you think about altering the frame rails?
I dont know how good you are with SolidWorks, but the beauty about modelling everything in 3D is that you can see any issues in advance, still you have done a pretty good job.
Mine has been on the track but its the same old problem with turbo's that is getting usable power, especially low down in the revs. I should imagine its like riding an early GP two stroke, fast as fuck but a right handfull [:0]

http://www.streetfighters.com.au/forum/upload/93773903330794.jpg

[Deano]

usable is what i want. i would rather have 180 usable hp than 220 unusable hp.

why don't you start up a thread about your bike. looks pretty trick

[BANDITROD]

i have just realized who you are motomax cheers for helping out my fellow members mate:D

[MotoMax]

Deano,

I noticed the turbo centre is below the engine oil level, what type of scavenge pump are you going to use?

and have you thought about a seperate oil system just for the turbo?

[Deano]

intresting you ask. i was autally working out the oil scavange earlier this week. the vdo oil scavange pump i would like to use is $240 and it will suck a bit of power aswell. i would prefer not to use anything electrical if i could.

the other option is the tried and tested reed valve in the oil pick up. then there is option 3 a emets pump that is crank driven designed for busas and later model gsxr as a oil scavenge pump http://www.emtes.se/products.htm they cost about the same as the vdo pump but should be more reliable as i hear the vdo pump tend to pack up easily

[Deano]

http://www.streetfighters.com.au/forum/upload/59906563494554.jpg


http://www.streetfighters.com.au/forum/upload/59906563478725.jpg


this is the unit installed on the same motor as mine

[Deano]

i was thinking of tapping into the same oil gallery that is in the above pic to supply oil to the turbo. i will just have to put a restrictor in the line so the oil pressure dosn't kill the turbo seals

[MotoMax]

If you use dash 3 brake lines for the oil supply, the turbo seals should be ok and like you said just use an inline restriction or even dash 2 lines should suffice.
The reason I asked about the oil scavenge is because I had all sorts of problems with oil getting past the turbo seals both turbine and compressor side. I think the emets pump is the way forward on yours, but remember the catch chamber below the turbo must be able to contain the oil that drains through the inlet after the engine stops. thats where electric oil pumps have an advantage, because you can run them after the engine stops, but like you said they sap a deal of power and wiegh about 2 or 3kg.

[Iceman]

Hey Steve, I had simalar problems with my GS, I think the turbo was a little low aswell. I ended up raising the turbo, adding a catch chamber and VDO pump.

[Deano]

started to make my new headers on the weekend. used some scrap bits of stainless to get them tacked into shape. will then take them off and make a jig from this set,

they are gunna look a shit load better than the other one i made, and best of all i can get the intercooler about another 15mm or so closset to the headers and frame rails

http://www.streetfighters.com.au/forum/upload/152116373223203.JPG


http://www.streetfighters.com.au/forum/upload/152116373213483.JPG

[Booster]

Deano are you purge welding ?
Thats going to look great and work even better.

[Deano]

yeah mate i purge them

[latheboy]

That does look better Deano ... Will the turbo be higher? Not that it matters with your fancy arse pump

[Deano]

no mate same height as before

[Deano]

http://www.streetfighters.com.au/forum/upload/618985743250416.JPG


well i got the new headers made. also made a jig to make life a little easier when making the headers. pic show the headers tacked up ready for final welding. i must say it is a prick of a job making these headers mostly cause they move so much when you do the final weld. next set will be welded in a different sequence in hope that the movement will be minimized.

made a list of the oil line fittings that i need today. 25 in total and all those fittings only require about 1.5m of hose.

still have a to do list as long as my arm but still on track for an end of year completion.

[BANDITROD]

fuckin awsome mate i will be having a good chat with you at gp mate thats for sure

[evad]

--Hey Dean, you do good work [:p][:p] Very nice. How long to lift off?

[Deano]

quote:Originally posted by evad

--Hey Dean, you do good work [:p][:p] Very nice. How long to lift off?


will still be awhile mate. will be taking some time off work soon so should get alot more done.

hopefully will get all fab work done within the next month then just the wiring, paint, computor, tuning, suspenion rebuild, engineers cert and reg,

if you say it quick it don't sound like much work

[DCRacing]

Hey Deano, you should take a wander down memory lane and have a look at what you have come from to what you are doing now. Bloody impressive.
i love the way this whole thing has evolved and what you have come up with, top stuff.

[latheboy]

25 fittings ????? WTF dude, where the hell are they all going to fit???
Good job by the way, if you pre-heat it, it wont move so much after welding ... give that a crack

[Deano]

quote:Originally posted by DCRacing

Hey Deano, you should take a wander down memory lane and have a look at what you have come from to what you are doing now. Bloody impressive.
i love the way this whole thing has evolved and what you have come up with, top stuff.


yeah its nothing like what i set out to build. differnt frame, differnt tail, now a fighter instead of faired.

i guess i will have to stop changing my mind at some stage

[Deano]

quote:Originally posted by latheboy

25 fittings ????? WTF dude, where the hell are they all going to fit???
Good job by the way, if you pre-heat it, it wont move so much after welding ... give that a crack


when you hide the oil cooler in the tail you really should think about where the lines are going to run. i didn't.

there will be oil line going every where mate trust me

[KATO ZX7]

Hiya Deano.
Mate what your creating and making is bloody awsome!!
You should give up your day job :D

[Fight_fan]

Very nice Deano! 1st class as always man! :D

[DCRacing]

So Deano what happened to the RR fairings? do you have molds of them or do you know where i can get a set from? want to set up the 88 model that i race with a set.

[Jockney Rebel]

nice pipe work dean ...as for yer oil lines you might try synflex hose its lighter than rubber and as long as thers no sharp bends its as strong,you want 3130-06 maybe

[Deano]

at this stage mate i am just gunna use -8 braid. might rethink my options on the oil cooling. was gunna just have a head cooler but it seems that the head cooler will need -10 lines. i may just have to come off the standard cooler outlets. they are -08 out of the sump.

not sure yet

[Jockney Rebel]

that sounds like a plan, anyway its lookin the bollox mate ..

[Deano]

quote:Originally posted by DCRacing

So Deano what happened to the RR fairings? do you have molds of them or do you know where i can get a set from? want to set up the 88 model that i race with a set.


they weren't my fairings mate. i was going to make a mould but never did

[Deano]

have spent a bit of time in the shed lately. got the intercooler finished. have to have the flange on
the turbo machined as the intlet to the cooler pulled a fraction one way when welding causing the intercooler
to sit a little off square.

i am rather impressed with the way it turned out. all the gaps between headers/frame/motor/forks on steering
lock turned out spot on. just a pity about the welding movement.

http://www.streetfighters.com.au/forum/upload/1040039353259270.JPG


had the wastegate machined off the turbine housing. ported the wastegate hole slightly. more porting before it is done.
also had to deepen and retap the flange holes.

http://www.streetfighters.com.au/forum/upload/1040039353236125.JPG


got my projector headlights. made up a temp mount so that i could measure everything up and draw up a more
appealing bracket and get them laser cut.

http://www.streetfighters.com.au/forum/upload/1040039353232059.JPG


decided to make up a new plenum. the old one would have worked ok but was a prick to fit and take out of the frame.
it would scratch the back of the plenum as i made it just a little to big. this one is 5mm smaller at the back and fits
like a glove. still got some work to finish it as you see but should be done i next couple of days

http://www.streetfighters.com.au/forum/upload/1040039353244533.JPG


got my layout for my gauges sorted, plan to have the digital display sitting on the triple clamp under the boost gauge

http://www.streetfighters.com.au/forum/upload/1040039353221913.JPG

[latheboy]

Nice welds on the plenum dean, the only thing i dont like is the head lights ... Under and over lights are GHEY .... Ill be back on tuesday if you would like me to make some swarf for you, and i need to pick up my stuff from the GP .. sorry bud i forgot all about it..

[Deano]

forgot to tell you it is at shano's mate. thourght he would be closer to you so left your gear their

[BANDITROD]

fuckin nice work deano lookin great good too see it all coming together for ya

[Gix11]

THat's is some awesome shed building there mate! I'm really impressed. I'm thinking we may be seeing this one in April hey?????

[Deano]

quote:Originally posted by Gix11

THat's is some awesome shed building there mate! I'm really impressed. I'm thinking we may be seeing this one in April hey?????


yes mate at this stage i should be able to get it to the fools run.

still a way to go but i feel i am on the home stretch.

once the up pipes are done and bov put on i will be onto the smaller stuff like finding spots for the electrics, plumbing the oil lines and making the brackets for the gauges.

[Fight_fan]

Fuckin ace Deano! Cant wait to see it mate, very cool!

[Razorback]

quote:Originally posted by latheboy

Nice welds on the plenum dean, the only thing i dont like is the head lights ... Under and over lights are GHEY .... Ill be back on tuesday if you would like me to make some swarf for you, and i need to pick up my stuff from the GP .. sorry bud i forgot all about it..


Sorry but its scientifically proven that under and over lights increase your attractiveness to women by 34% and your testicle size by a further 22%

http://www.austincc.edu/gmarion2/farside.jpg

[debaser]

Real nice work, the best stuff comes out of sheds. What happened to the old plenum? Do you still need it? I'm still thinking about suck through for mine. I am hanging out to see how the fuel injection setup works for you.

[fimpBIKES]

love it, once again!

the lights are sweet, fuck what latheboy (or anyone else) thinks [:P]



have you got the veypor running, mine was always fucked...

when you planning to fire it up? make sure u have a vid cam ready!

[zx12argh]

good work deano - can't wait to see this at the fools

[Deano]

ivan thinks they are ghey cause he has under and over lights and he is ghey.

the old plenum aswell as the old headers will go into the 'one day' box. you never no when you may need to turbo another bike.

veypor runs great. lives on the race bike at the moment. have been using the datalogging etc and downloading it to the laptop. great bit of kit i think.

back out to the shed now to finish off the plenum

[debaser]

quote:Originally posted by Deano

ivan thinks they are ghey cause he has under and over lights and he is ghey.

the old plenum aswell as the old headers will go into the 'one day' box. you never no when you may need to turbo another bike.

veypor runs great. lives on the race bike at the moment. have been using the datalogging etc and downloading it to the laptop. great bit of kit i think.

back out to the shed now to finish off the plenum


Ha ha, I had a one day box. Now it is a ever expanding one day pile. My other half loves it (not). If that 'one day' turns into an 'ebay' box pm me first I will make an offer for the plenum and headers.

[Deano]

no worries mate i will keep you in mind

[Deano]

been a while since my last update.

have got alot done since then.

got the up pipes and blow off valve finshed. had to kick the bov a little off square so that the vacuum
port on the top would clear the breather box


http://www.streetfighters.com.au/forum/upload/331809108226955.JPG


got the head cooler take off from bandit rod. thanks mate a dam site easier that making them

http://www.streetfighters.com.au/forum/upload/331809108351226.JPG


got my fittings and braided hose and made up some of the oil cooler lines.

to neaten things up a bit i am running the oil through the subrame stays.

http://www.streetfighters.com.au/forum/upload/33180910856524.JPG


http://www.streetfighters.com.au/forum/upload/331809108224473.JPG


http://www.streetfighters.com.au/forum/upload/331809108210268.JPG


boost gauge mounted

http://www.streetfighters.com.au/forum/upload/331809108196145.JPG


oil feed to turbo

http://www.streetfighters.com.au/forum/upload/331809108226672.JPG


drilled and tapped the banjo bolt for the oil feed to the turbo so that i can screw in a mikuni main jet to give me
control over the amount of oil going to the turbo. if i need more i will get a large main jet (or drill it out)

http://www.streetfighters.com.au/forum/upload/331809108353102.JPG


Got the wastegate mounted and welded. just got to give it to Ivan to machine the flange flat again after i bowed slightly after welding

http://www.streetfighters.com.au/forum/upload/331809108215124.JPG



a big thank you to ivan for alot of machining over the last 4 weeks, the headers needed macining flat were they bolt tothe
turbo. the hole needed boring for the wategate pipe. the subframe rods need to be drilled through for the oil to run thorugh them
and the flanges that the wastegate bolt to had to be machine back flat afte welding also had to put a 1 degree taper on the turbo compressor outlet to bring the intercooler back to aquare. cheers mate i owe you one.

[timbo]

Coming along nicely mate love the black fittings. Keep up the good work.

[geesexar]

man i love this build deano...keep it up mate[:p]

[BANDITROD]

oohhh sexy mate i am itchin for this to fire up

[latheboy]

No problem buddy,
I'm glad its all coming together and will make brum brum noise's soon

[mr.zxr]

great work mate. love the oil cooler under the fairing and all the plumbing to it. my turbo zxr900 runs hot in traffic so you've got me thinking. nice one! can't wait to see more pics.

[Deano]

quote:Originally posted by mr.zxr

great work mate. love the oil cooler under the fairing and all the plumbing to it. my turbo zxr900 runs hot in traffic so you've got me thinking. nice one! can't wait to see more pics.


not sure how it will go but hopefully it will keep it cool enough.

your running a SM4 arnt you? looking to use the same ecu will be looking to get one very soon.

[fimpBIKES]

loving every update, you've got a great style in how you plow through obstacles

10points!

[Fight_fan]

Yeh onya deano! Well done, all the way! Cant wait to see it in april!

[mr.zxr]

quote:

not sure how it will go but hopefully it will keep it cool enough.

your running a SM4 arnt you? looking to use the same ecu will be looking to get one very soon.

yeah the SM4 is great. i had a microtech air/fuel only and it ran but nothing like it runs now. i gained 20hp, using less fuel, and so much better ridablity. my whole setup is very similar to yours. i have a very similar plenum and intercooler setup. if your still after a scavenge pump, MR.TURBO in the states do a few different ones. i run the low volume pump and it works ok and was only $100ish.
have fun.

[Deano]

thats food for thourght. might have to have a browse at the mr turbo site.

intresting what you say about the microtech. i am hoping i will avoid issues that others have had by getting a good computor from the start.

cheers.

love the signature - so true

[Watto]

lookin good Deano :D

Re the head cooler takeoffs - are they a custom made part or does Rod know of a place that does em - just curious of course :D