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

[CBRRRT]

I felt so sorry for ya I was willing to pitch in to help you get another one, fuckin rotten bastards, and I'm on the rock and roll. Bunch of cunts!!

Nice one!

[BANDITROD]

hello is it done yet ;)

[TurboKat]

Got a call from the Mean Dean Machine tonight, he needed a timing light run up to Dyno Dynamics as a matter of urgency as his had refused to be seen near a Streetfighter & gone on strike, no biggy so I shot up to Lilydale & dropped mine off, then he & D.D. resident tuning Guru Jerry set about checking the static timing before dynoising it, all was well after a tweak & it was strapped to one side of the AWD dynamo meter.
http://www.streetfighters.com.au/forum/upload/20004694776336.JPG

Jerry doing his stuff.
http://www.streetfighters.com.au/forum/upload/20004694778880.JPG

Bit of header glowing action [^]
http://www.streetfighters.com.au/forum/upload/20004694777582.JPG

Deano looking well chuffed, little did he know what was about to happen [:0]
http://www.streetfighters.com.au/forum/upload/20004694780321.JPG

I didn't get a pic of the turbo actually exploding & sending red hot debris flying everywhere but this is a very unhappy Deano mopping up the aftermath of the "incident" [V]
http://www.streetfighters.com.au/forum/upload/20004694775664.JPG

[TurboKat]

The last pic doesn't show it but the turbine side of the snail is completely obliterated [V] the explosion was huge & Garrett brand shrapnel was all over the workshop, Jerry reckons the blowup was caused by a design fault in the dyno itself (designed & fabricated by Latheboy) which overloaded the electrotrimodulator unit & caused the turbo to spin to 1,000,000+ RPM which resulted in a major turbine failure :(
The good news is that the motor made 326 HP :D before the turbo blew.
Proof that you can't keep a good man down is that Deano assures me that he will have another snail bolted in place before the bikes long awaited debut at the Phillip Island WSBK round this weekend ;)

;);););););););););)

[BANDITROD]

well thats good and bad news i supose 326hp fucking wicked

[TurboKat]

Might have been 362 HP Rod, I'd had a few beers & I'm easily confused ;)

[Iceman]

with this thread being ever increasinly filled with bullshit, the only part I believe is that it ran and was on the dyno.

[TurboKat]

[:0]

[BANDITROD]

i call bullshit ;)

[Iceman]

:D

[wackyrider]

With this thread you never know.
but that's some power its throwing out.....

[Gix11]

362hp! Fuck me, are you for real??

[TurboKat]

Are you calling me a liar? ;)

[BANDITROD]

YES ;)

[wackyrider]

[:0][:0]

[TurboKat]

OK... I might have lied about the power figure a little bit[B)]
But that's at least what Deano is expecting to make because that's what Ozkat told us his home built GSXR1100 turbo made when we were at AFR '06 & that only had blow through carbs (nobody actually saw, heard, touched, tasted or smelt Ozkat's [u]alleged</u> turbo GSXR 1100 & there were no pics of it or dyno sheets but I still believe him.) Dean's has electric fuel injectoring so it'll hafta make more than Ozkat's... won't it?

[BANDITROD]

bwahahahahahaha

[Surt]

what will ya do when real wolves come along?...[}:)]

[Fight_fan]

^ Good point Surt! Darren u could be ruining this for us all when the wolves really do come mate! ;)

[latheboy]

Gerry was VERY impressed with the turbofighter... its a shame about the fail, it was so close but its safe for the moment..
Pity i couldn't be there....

[Weaselman]

^^ why so you could laugh?

[Deano]

you guy want to hear the truth?

[BANDITROD]

yes yes yes yes yes

[Iceman]

No, we want to see the video!

[BANDITROD]

&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;&lt;yeah what he said

[Deano]

what video?

[TurboKat]

The one of you slapping it into Crutchy's friend... you sly dog you ;)

[Deano]

quote:Originally posted by TurboKat

The one of you slapping it into Crutchy's friend... you sly dog you ;)


dont no what you meen darren

anyway we got alot of the fuel map tuned and all was going well till the plastic fitting on the end of the electric oil pump broke off causing oil to go everywhere.

no hp figures yet as it was all just tuning

[latheboy]

Who's the friend Deano???? go on tell us ...

How long where you there for?

[BANDITROD]

anymore progress deano

[Deano]

yeah mate. got a new pump yestrday. have a bit of work getting it to fit tho.
should be up and running today,

[BANDITROD]

woohoo let me know how ya go mate

[Hagarr]

Can't wait to see the results whatever HP you get!! looking good!

[Deano]

got the bike running on thursday arvo with the new pump and remodded sump.

loaded it onto the trailer and went straight to phillip island.

road the bike around a bit. started well but was rich with the warm up and cold start enrichments. didn't think this would be to much of an issue till i fouled a set of plugs on saturday morning.

quick trip home to get more plugs and the lead and laptop to trim out some fuel from the enrichments ment i was up and running again.

they say boost is addictive and they are right. it makes all the right noises. when the wastegate opens it sounds great. everything sounds even better when it is just the dump pipe. i rode it around with only a dump pipe on sunday.

so far it is very good and should only get better when the rest of the tuning is done.

[Iceman]

Well done Deano, I'm looking forward to seeing it.

[BANDITROD]

fucking awsome mate have you had much of a chance to give it everything yet

[opindown]

good work mate, sounds like a shit load of fun

[latheboy]

It sounds great and goes even better....

[Fight_fan]

Awesome Deano! Cant wait to see it mate...

[fimpBIKES]

CONGRATS DEANO!!!

have fun tinkering maps for all eternity :D

[zx12argh]

Good stuff deano - cant wait to see it!

[Deano]

as we all know the bike now runs. still needing some more tuning to get it right but getting there. alot has happened in the last month leading up to getting it running so here is a few pics of what has happened.


http://www.streetfighters.com.au/forum/upload/750805169202447.JPG

couple of fittings and a small piece of hose loops the fittings together that normally head to the oil cooler.
you can also see the coolant temp sensor in the back ground in the front of the sump

[Deano]

got myself a tech edge 02 meter. little display sits nicely on the top triple

http://www.streetfighters.com.au/forum/upload/750805169235414.JPG

[Deano]

and mounted the controller ontop of the fan. not sure how hot it will get so i will have to keep an eye on it

http://www.streetfighters.com.au/forum/upload/750805169243438.JPG

[Deano]

made the turbo scavange arangement. used a goodridge check valve (blue thing) to stop oil running back to the turbo when the motor is stopped

http://www.streetfighters.com.au/forum/upload/750805169226210.JPG

[Deano]

and just this weekend after pulling everything apart again rewelded over the welds on the intercooler as i wasn't happy with them. wanted that 'professional' look

also gave it a polish

http://www.streetfighters.com.au/forum/upload/750805169239305.JPG

[Deano]

fitting is welded on the inside of the sump

http://www.streetfighters.com.au/forum/upload/750805169168759.JPG

[BANDITROD]

lookin fucking good mate

[Deano]

so this is what it looks like unde the tank now.

wont be so bad once the wiring is finished and i can tape it all up and neaten everything

http://www.streetfighters.com.au/forum/upload/750805169291781.JPG

[Deano]

made this little vacuum/boost manifold.

it gets boost and vac signal from the take offs on the t/bs between the butterfly and the inlet valve. i have 1 dash 4 line going to the bov, 1 dash 4 going to the map on the ecu and the other little white line is the boost gauge. this also helps balance out all 4 cylinders to allow for differences in expansion from heat etc. in some cases if all cylinders are not linked you can get certain cyclinders running lean and others rich. you got to remember that the injector only puts in a preset amount and dosn't no if cyclinder 2 is 3% further open than cyclinder 1. carbies dont have this issue and they rely on air speed through each carby. the more air the more fuel. Fi don't work like that,

hard to expain but you get my drift.

http://www.streetfighters.com.au/forum/upload/750805169271243.JPG

[Deano]

so the list of things to do before afr is as follows

paint body work
make zorst hanger bracket (wont be needed if just running dump tho)
finish tuning
paint/powdercoat wheels.
fix fuel delevery problem
make new rods for the subframe as the first rods i made to take the oil had pourus welds and no matter how much die grinding and rewelding they just wouldn't seal.
make spacer for window for lock up clutch to clear

unfortunately i don't have the time to pull the motor out and paint it along with the chassis but i guess it will have to wait till after afr

there will also be alot of detail work that i just wont get a chance to do but i guess it should be definately right for next year. and also sporting 10lb boost by then.

[timbo]

Go you good thing

[latheboy]

quote:Originally posted by Deano

and just this weekend after pulling everything apart again rewelded over the welds on the intercooler as i wasn't happy with them. wanted that 'professional' look

also gave it a polish

http://www.streetfighters.com.au/forum/upload/750805169239305.JPG



That is awesome, great work on the cooler (and everything else too:D)

[Deano]

i am happy with it.

needs a professional polish tho. i hate polishing

[evad]

Hey Deano, well done mate... Your ally welding looks wicked mate!!

[HueyonaBlade]

Bloody hell mate you have really got a handle on using the tig , bet you rapped you jumped in the deep end with it:D

[Deano]

it has its moments mate. fair bit on luck involved tho

[Gix11]

Check those welds! Fuck mate, you've nailed it!

[Watto]

schmicko Deano [8D]

[Chase]

Mate that's awesome work.

[Deano]

http://www.streetfighters.com.au/forum/upload/150561761251090.JPG


had to make a new fuel pick up and change the position of the pump to lower and right at the back of the tank. my theory of baffling the tank and having the pump up the front didn't work as i had to have aobut 10lt of fuel in the tank at all times to get consistant fuel pressue. not ideal.

the new 'sump' is mounted at the lowest part of the tank and has a sort of baffle in it aswell so fuel shouldn't get out of it easy. the fuel return also exits close to the entry to the pump so hopefully this will work well. should have done this from the start. oh well we live and learn

[Deano]

http://www.streetfighters.com.au/forum/upload/150561761275445.JPG


pump mounted to the access lid with filter and hose work.

[Deano]

http://www.streetfighters.com.au/forum/upload/150561761268127.JPG


shano took care of the wiring. only wired enough to make the engine run. it will end up very neat when the rest of the wiring is complete and i can tape it all.

[Deano]

http://www.streetfighters.com.au/forum/upload/150561761260753.JPG


and all assembled again. ready for dyno for final tune then off to afr.

stil a bit to do, gunna give it a token coat of matt black and just tidy up a few things.

[ozzy1100]

fuck deano i love the way u work
in a former life i was a fitter and i love builds like this well thought out,
well exed and nothing done just for the sake of it

[BANDITROD]

thats wicked dude well done man

[Fight_fan]

Awesome work Deano! Bring on AFR!

[TurboKat]

This thing has to be a shoe in for Best Shed Built Fighter doesn't it? I'm voting for it anyway, because it has actually been built in a tin shed ;)

[Deano]

well i squirted around some matt black over the last few days. in the final throws if assembly, have a date with the dyno today at 4pm so hopefully all thing going well i should have a tuned bike for afr and also a hp and torque figure for those that are intrested in what result mt home made turbo kit will produce

fingers crossed

[Fish]

Pics of matt black paint job please!

[latheboy]

Dont trust the dyno guy, i hear he doesnt know what he's doing...
See you at 4

[Deano]

http://www.streetfighters.com.au/forum/upload/986159705287040.JPG



http://www.streetfighters.com.au/forum/upload/986159705302251.JPG


fairly happy with the overall look. still tonnes of detail that is not done and wont be done before afr.
an before you tell me about the blue seat i am actually picking up a black seat at afr so that should make it look even better

[BANDITROD]

fuck yeah man thats fucking awsome dude i love it

[Weaselman]

your bikes slow! [B)]:D

[Fight_fan]

Yeh that looks gr8 dude! Well done hey...

[Fish]

Noice, oh you need to change the blue seat to a black one. I know you said you were going to but i'm an ignorant prick.

[Deano]

didn't go so well last night.

found that after 8k it started misfiring. the ecu is reporting 'not enough cyclinder trigger events' must be a problem with the sensor somehow. Ben has suggensted changing the polarity so will give that a go. unfortunately i cant get back on the dyno before fools so not sure if the bike will get to fools since i cant ride it over 8k at this stage

[Fight_fan]

http://i532.photobucket.com/albums/ee325/GIX711/Funny%20Pics/1230629646248eq7.png

[Fish]

FAAARRRRRRKKKKKK!!!!! Not good Deano, I was looking forward to seeing this one in action the most.

[latheboy]

quote:Originally posted by Fight_fan

http://i532.photobucket.com/albums/ee325/GIX711/Funny%20Pics/1230629646248eq7.png

Full credit to deano he only get to the first pic and didnt go mental... I would have fucking lost it... This is what happens when you try something new, unfortunatly there is always a hold up and some scratching of the head to work it out...
After a few little things to be worked out this bike will be radness

Awesome bike, looks great with the new paint, sounds rad and there are flames ...

[BANDITROD]

fuck dude not good news there is gunna be a dyno there you know

[Deano]

couple of things to try but dont no if that will fix the problem. working my guts out now to get a frame made to put 2 bikes in the back of the ute.

if i take my race bike at least i can practice my race starts, i am shit at them so that will be one good thing to come out of it. at this stage the turbo bike will be coming but cant be reved over about 8k

[Booster]

Welcome to drop by on the way, looks like i'm not going but be happy if i can help in any way.

[Iceman]

Haven't you had enough of other peoples bike this week Greg?

[Deano]

thanks for the offer but about to take off now to head to afr.

have squeezed the race bike on the ute aswell so at least i will get a ride

[Deano]

due to popular demand i best let you guys no what is happening to the turbo bike.

after alot of help at afr from exben i came home with a bunch of things to try to get the bike revving over 8k.

after talks with Ian from Autronic we had the data log running logging many things that included the crank and cam sensor. the initial problem that the ecu reported was 'to few cylinder pulses' the first thing that you think off is the crank (cylinder pulse) trigger giving an incorrect reading. after data logging this trigger we noticed that the output from the trigger was spot on with no mis triggers. this then causes us to look at the cam sensor, even through the ecu was saying the crank triggers were the problem it was not so. by saying there were to few crank triggers is assuming the sync (camshaft trigger) is 100% correct. if the cam sensor is up the shit like it was then the crank looks like it is playing up. hard to explain i no but just trust me on this one.
http://www.asfphotos.com/upload/1243309756.jpg


this pic is of the cam trigger when i first installed it. the sensor is crank sensor from a gsxr and the trigger is the screw sticking out of the alloy,

http://www.asfphotos.com/upload/1243304851.jpg


this page of data log shows the problem with the sensor. the crank pulses are very consistant but the sync is not.

http://www.asfphotos.com/upload/1243352402.jpg


this pic shows the new trigger. i ground down a bolt head to replicate the trigger that is used on the crank as that was what the sensor was designed to have as a trigger. this didn't seem to help so i changed out the sensor with a new sensor and then that seemed to fix the problem.

once i did get the motor to rev without giving an error code it did seem quite 'dirty' above 8k but i thorught it would be one of 2 things or a combination of both, the motor had not been mapped all above 8k and the tridon brand ignition module that i was using wasn't up to the task. the easy fix was to buy a genuine bosch module. this improved things greatly so now it is a matter of fitting a bigger turbo and heading back to the dyno to turn out 200 odd hp

[pesh]

nice work Deano . looks like u've got that shit sorted ,

[timbo]

Shit hot mate glad to see some progress in the right direction 200+hp hear we come

[Fight_fan]

Sweet! Awesome stuff Deano!

[HueyonaBlade]

I haven't a clue what your on about , but sounds like it could go fast one day;)

[wackyrider]

Goo dluck mate. Sounds like you got it sorted.

[jzbusa]

2 words Deano - disco potato

[scotty]

nice one deano

[mr.zxr]

What sensor did you end up running mate? Glad to hear you got it running.

[Deano]

used the same sensor as the crank sensor mate. just the standard gsxr one

[Deano]

time for an update.

since last time i have done what may seem like not alot but seems to take forever.

i have gone for a bigger turbo. this one is a ball bearing GT28R (gt2560r) from an s15 silvia.

this different turbo has the same 3 bolt compressor outlet flange but they have rotated the 3 bolts about 20deg meaning that the old intercooler dosn't fit. i could have cut the bottom tank off and make a new tank but thourgh i might aswell just make a new intercooler alltogether.

http://www.asfphotos.com/upload/1264731308.jpg


looks the same really just now have a black seat

[Deano]

http://www.asfphotos.com/upload/1264754049.jpg

[Deano]

http://www.asfphotos.com/upload/1264701011.jpg


what the dash will look like.

i only have the fuel pressure gauge for tuning.

have a motogadget mini on the right and boost and wide band air fuel on the left

[Deano]

http://www.asfphotos.com/upload/1264695508.jpg


made a billet fuel rail and now have some quick disconnect fuel couplings under the tank to make life a bit easier

[BANDITROD]

thats awsome mate i am happy my ride is with you cos you know damn well what you are doing when it comes to turbos and shit