Project Budget Turbo Dragqueen

[Jon]

Not done lot the last few days. Spare times been spent sitting 50 foot up in the air on my roof fixing roof slates which have been missing for decades. Lol. Bit of a mission but got there in end n didn’t fall off which is always a good thing at that height. Quick smear of concrete under the top caps somepoint when get a chance n do another good few years.

Anyway bike related guff. Bolted up the intercooler n all the clamp/mount arrangement I sprayed other day. Plain shiny blik! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851579.jpg

Some more scavenging turned up some 50-ish mm internal bore stripy water pump hose offcuts and an offcut of thinwall alloy scaffolding tube out of a rubbish skip.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851584.jpg

Water pump hose reinforced with solid plastic and doesn’t crush even when stand on it. Good 5mm thick wall. Can be bent to slight curves but that’s it. Really tight fit on intercooler and alloy piping, but a roasting with a heat gun managed to soften it enough to get into place. Tooks some amount of heat to get any deflection in it so more than capable of withstanding turbo air charge temp. Didn’t like the look of it though so wrapped it in some blue silicone tape, and polished up the alloy tube. Looks alright and for all the world like silicone piping close up, but free. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851583.jpg

Bolted up n looks funky n better than scrap. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851580.jpg

Need to buy a couple of silicone bends to complete side plumbing and a couple for front plumbing between turbo and intercooler. Found a cheap place for them though. Stripping my ninja down slowly as that’s my next project in line and noticed has same battery I need for my bandit on it. Ninjas getting full revamp same as bandit so going to be off road for good while so makes sense to nick its battery for bandit and replace it 6 month – 1 year down the line. Saves a few quid buying one for bandit too at moment.

Still working on shaping up side scoop which will take a while too. Apart from that its now buying bits like the silicone bends I mentioned, a boost sensitive fuel pressure regulator, and a boost guage. Think that’s about it. Reckon maybe £60-70 for that lot n that’s everything bought for it. No dosh for it at mo though so going to have to wait a while. Not much point in buying bits here and there as all coming from same company so buy together will save fortune in postage to highlands of Scotland. Chip away at side scoop filler/paint/airbrushing in meantime till have the cash.

[Jon]

Have been doing something honest. Lol. Been prepping n filling n primering, etc some gixer bodywork last few days so grouped side scoop in along with that lot since going through same process to black basecoat same as bike panels. Saves wasting time n materials.

Looking pretty straight now tho so will be black in couple days along with job Im on n can start airbrushing it up like other side.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851625.jpg

Been working on starting my ninja rebuild too in evenings as yer can see from my new build thread. Busy, busy. Lol.

[Jon]

Times being split between this project and my ninja cafefighter project so moving forwards slowly. No great rush tho as cant really move things forwards without cash for rest of bits Im needing (fuel pressure regulator, few silicone bends, etc). Bout £80 worth I reckon n that’s everything I need bar engine oil. No free cash at mo n very little time as works busy.

Speaking of oil system, Emoe`s sending up a curved Gixer oil cooler and hoses for me to use for price of postage (cheers bud!). Can get that cleaned up n painted n bolted on, etc when arrives.

Started on airbrushing up other side scoop. Still in early quick sketch stages, but I`ll finish it off next few days in between things n get it bolted on.

http://i61.photobucket.com/albums/h63/pitstop-paint/LHSscoopstart.jpg

Got a long harsh winter on its way up here so be lots of shed time. Lol. Weathers too good at moment so been out n about on my Harris Z enjoying it. Empty mountain roads n no traffic/junctions/police. Bliss. Too good to lock myself away in shed. Lol.

Updates when get some free time/dosh to do some more. Lol.

[Jon]

Finished off scoop artwork last few evenings. I`ll drown it in 2K clear tomorrow probably n can get it sanded/polished n bolted on by weekend hopefully.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/LHSbanditscoopdone.jpg

Project dragging its heels at mo, but that’s just the way it goes sometimes.

[el sammo]

lookin great man comin along nicely

[Jon]

Sat n sanded n polished up scoop tonight. Looks pretty good. Much same as other side, but not symmetrical other than hand shape.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/LHSBanditscoopdone1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSBanditscoopdone2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSBanditscoopdone3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSBanditscoopdone4.jpg

Also blagged some gloss black self adhesive edge trim. Just clips on and is pre-glued. Going to cover the outer edges of the scoops as keep catching other side moving past it in garage so will save chipping the paint n neaten things up a bit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/LHSBanditscoopdone5.jpg

Gonna get out tomorrow n get scoop bolted on n trim applied n make a list of everything I need to finish the bike and suppliers/part numbers, etc so can chip away at buying wee bits for it as have some spare cash. Not needing much tho. Fuel pressure regulator, few silicone bends n odds n sods.

I`ll kick trike out of garage so have plenty room to work tomorrow n get some pics of other side of bike for once n some front shots, etc as looks mad head on. Lol.

[Jon]

Rolled my trike out garage door today so had loadsa space instead of squeezing between n climbing over bikes to work. Lol.

LHS side scoop bolted up. Also trimmed the edges of both scoops. Works really well. Press into place n job done. Neatens up the edge a lot n nice gloss black finish like paint so doesn’t stand out as such. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow01.jpg

Couldn’t resist having a seat n grabbing stack of pics while had space n sunshine. Given me new found motivation to crack on with it again tbh.

Full frontal pictures as requested by few folk (the bike not me!, lol). As far back as I could get from bike in garage. .:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow02.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow03.jpg

Back view of bike showing height next to my Harris.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow04.jpg

Back shot showing width, etc.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow05.jpg

Sitting on it shot.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow06.jpg

Other side shot fer once.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow07.jpg

Sun was out n used to working on bike in dark of garage, so couldn’t help taking a pic of my one-eyed monster!....................the tank I mean. Sheesh. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow08.jpg

LHS again.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow09.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow10.jpg

Some shortarse chunky hairy biker twat appeared out of nowhere with hair down to his arse n jumped on bike making `broom broom` noises. Its not me with me 10 year old daughter taking the pics honest!...........lol. Im only bout 5` 7” or 8” to give an idea of scale. Pretty low if I can bend my knees. Lol. Whole bikes below waist level. Has a very squat wide look to it. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow11.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/banditfernow12.jpg

Made a list of what I need to finish so buy odd bit here n there as have funds. Noticed a couple things as had space to stand back from bike.

1) Side scoops although mad Judge Dread wide stance, have a better ground clearance than thought. Leant the bike over bout 45 degrees n still not touching ground. More than expected tbh. Not gonna be a throw around the twisties bike ultimately, but way more leanability than thought there would be. Ridden chops, etc with half that lean angle n been practical in a point n squirt fashion.

2) Although lean angles damn good compared to what was in my head, the number plate is too low as will touch down easily. Need to make a new arm for that to angle it up a bit I think.

3) Shoving n lifting about the bike in garage revealed its not as heavy as anticipated. No heavier than my other bikes even though its long/low n chunky.

4) Its nice finally having a bike I can sit on n touch the ground with bent knees, instead of tip-toeing. Lol.

So yeah just few bits to make n buy, etc, but I`ll keep chipping away at it when time/funds allow. Liking it tho. Just so `out there` n different to norm, and my other bikes. Folk will like it, folk will hate it, but if the only thing everyone can say is the airbrushing is good then Im happy. Rest of bike is my oddball tastes ultimately.

[Jon]

Been having a go at number plate position last couple evenings since realized it was too low to the ground.

Made another slightly longer arm, and notched it to clear swingarm. Also routed out this bolt with a knurled little knob on end. Think its off an old computer case or something. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/newnumberplatesetup1.jpg

Quick recessed hole, a small spring and a nyloc nut on end.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newnumberplatesetup2.jpg

Quick pull of knob to compress spring and nut slips inside arm flush with surface. One basic n neat locking mechanism. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/newnumberplatesetup3.jpg

Number plate sits a lot higher angle n gives plenty ground clearance.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newnumberplatesetup4.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/newnumberplatesetup5.jpg

Locked in position so bit safer than spring setup. Quick tug of little knob thingy n unlocks to swing down into spec panel setup.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newnumberplatesetup6.jpg

Lock re-engages automatically when raise number plate back up again. Not a big job, but one of those small ones that add up. Lol.

[Gitzy]

Nice work Jon, a little wide for me, but your workmanship has to be commended, I reckon we'll be seeing this in SF Mag feature sometime soon. Definitely different mate.

[Jon]

Yer its wide, but practical enough. Wanted different, n think thats what Ive got. lol.

Be in the mag somepoint yer. Been discussed with MDM.

Get it finished somepoint then start looking for someone wanting paintwork who`s got a 11/12 lump sitting doing nowt in exchange. Bigger turbo n go for silly bhp. lol.

[_M_]

nice number plate bracket ;), and awesome paint job.

[Jon]

This projects not been forgotten about, just on backburner as need dosh for last few parts. What with getting our hearse through its mot and Xmas coming n 3 kids, etc its been put to back of priorities money wise understandably. Been busy building my ninja (project budget cafefighter) to keep me busy in meantime. lol.

My fab wife was just asking me about what parts Im needing, etc for bandit with a view to getting some of them ordered up so should be back onto making/fitting bits soon enough.

Saying that tho Im still putting in the hours on the bike even though theres little to show for it at moment. Amazing how many small areas you find that you said to yourself "I`ll sort that later, then didnt". lol. Noticed clutch cable hanging on shed wall for example. Went to fit it n realised clutch lever just caught pass switch on back of switchgear when pulled in, so that was bars apart, then while had tank off noticed throttle cables still needed connected, then decided to neaten up few wires, lockwire few tubes, etc, etc, etc. Neverending. lol.

Been doing a lot of wee jobs on bike over the last few weeks, but nothing worth sticking up pics of really. Be some posting soon enough though as start getting parts bought n fitted, etc.

[Jon]

Been waiting best part of 2 weeks now for my boost sensitive fuel pressure regulator to turn up. Biggest part I had to buy n eventually found cash for it. Got hoses n clips sitting ready to connect it on and a gap under the tank reserved, etc, etc. Cant do fuck all till shows up tho. Pissin snow has backlogged RM big time.

Couple silicone bits to buy too when get cash n thats about it tbh. Oil cooler n hoses comin, then can fill the engine up with oil n start settin everything up, etc.

I should be excited, but tbh I'm really not. In one of those lost interest in bikes moods at moment. More interested in building than ridin these days. Maybe its the weather got me on a downer. My Harris n trike havent moved in yonks.

[Jon]

Fuel regulator finally arrived today. Only taken couple weeks cos of snow backlogging RM. Hey ho what can yer do.

Tiny tho! Expected it to be about twice the size judging by close-up pictures on websites. Different tho when have it in your hand and something to compare scale to.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/fuelregarrived.jpg

Came with mounting bracket, etc for £42 delivered off Egay. Spent £8-odd on fuel hoses n hose clamps too to plumb it in. That takes my total build budget up to a heady £457 I think including the bike. Lol.

Bit of web research and found connections if any use to anyone else going through similar build?:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Malpassiregulator.jpg

Malpassi themselves state adjuster on top of unit gives adjustment of between 5 and 60 psi. I’m needing to wind it down to 2-3psi, but from other peoples experience its just a case of snipping a couple coils off the internal spring to reduce the spring pressure slightly. I’ll get a proper look when fitting tho.

I’m in middle of finishing off my ninja projects bodywork panels, but I’ll get it mounted n plumbed in some point this week. At least the space I had allocated on bike is a lot more than needed, which makes a change. lol

[Jon]

Well works on hold as waiting on helmets, etc through mail and nothings moving cos of snow. This is this morning when kids decided to decorate my hearse.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/regfittin1.jpg

About 4-5” have fallen since then easily. Still snowing too. Roads are useless as not getting ploughed or gritted round here so pretty much house bound at mo. Lol. My wifes on way back from Edinburgh right now, several hundred miles n 2 hour ferry crossing south from me. Dunno if she’ll be making it way weathers looking tbh.

But weather aside I’ve got some free time to get bike bits done since works on hold temporarily. One plus side of the shitty weather. Lol.

Dug snow drift out of way so could get into garage this morning. Had to take my hammer to a few spanners that had frozen to bike workbench overnight too. Lol.

After plumbing it in wrong once, plumbing it in twice again cos I wasn’t happy with pipe layout, and stabbing myself in hand several times with screwdriver (thankfully hands frozen cold so couldn’t feel it, lol) I got regulator plumbed in. Everything clamped up tight. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/regfittin2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/regfittin3.jpg

Old gauge out of random box of shite is off god knows what. Either a compressor or fuel system or something. God knows but should be enough to let me know if regulator working right on setting everything up. Can disconnect it out of system after that tbh.

One pipe from fuel tap, and larger bore one back to modified tank breather above fuel level.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/regfittin4.jpg

Havent chopped the internal spring yet, but only a couple minute job. I’ll maybe nip back out n do it later on once defrosted a bit. Bit sick of tools sticking to my hands with the cold right now. Lol.

Removing one of side panels while working on the bike and one of the lugs just snapped off. Didn’t put any pressure on at all. Mixture of extreme cold and me not feeling my strength properly as fuggin cold myself I think. A bit of swearing later I used my rivnut gun again to put a threaded insert in and a bolt to locate into rubber side panel fixing on frame. Works fine.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/regfittin5.jpg

On the downside when drilling the hole the drill bit caught n wrenched the drill sideways n right through the side panel. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/regfittin6.jpg

Again some more `colourfull` language. What can you do tho ultimately. Shit happens n all that. Quick sand/filler/touch-up n re-clear the panel n be good as new. Bit of a pisser, but nothing I cant sort easily enough. Paints something I can do.

[Jon]

Had a go at modifying the base pressure setting of the fuel regulator today. Thought it would be a 5 minute job, but requires bit more effort. Still a quick n easy job tho unless you split the unit and the spring, spring cups, and the allen key you’re using are dropped into the bike and across garage floor. Then you spent good 45 minutes with a torch on your hands n knees finding the parts. Doh! Lol. Cold hands are a PITA.

The adjustment of the unit is stated as between 5-60 psi by Malpassi themselves. I need only 2-3 psi above boost pressure for my setup so a bit of surgery is required.

Adjuster is on top of unit.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/fuelregmods1.jpg

Top chrome nut is just a cover though revealing screwdriver adjuster and locknut at bottom. Screw it inwards and more spring pressure = more fuel baseline pressure. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/fuelregmods2.jpg

Thought the spring would be in top of unit, but screwing it out and all you find is a pin on end to locate in spring collar inside unit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/fuelregmods3.jpg

4 allen bolts secure 2 halves of unit together. Remove them and you can see the inner workings are simple enough. Rubber membrane like a CV carb that moves with boost pressure into unit from plenum/carbs/intake. The more boost, the more movement of membrane n fuel valve below it, allowing more fuel pressure to outlet fitting and less returned to tank. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/fuelregmods4.jpg

I chopped small sections off spring with pair of snips till the top of spring sat flush with top of top cover, and 2 halves of unit sat together under they’re own weight with only the slightest pressure on spring. Worked out about a spring coil and a half or thereabouts. Don’t have to be too exact as adjustment screw had plenty adjustment for most needs.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/fuelregmods5.jpg

Put the 4 bolts back in and job done. Should now be able to wind base pressure down to 2-3 psi or less above boost signal line level, as long as return line to tank is decent size so as not to restrict pump outlet.

[Jon]

Been waiting couple of weeks now for the last of my silicone bends and a boost gauge to show up in mail. Xmas and new year seems to grind everything to a halt. Waiting on lot of spray work finding its way through it all too.

Been taking time out with family, etc in meantime, but tbh I kinda lost my way with it all for a while. Was seriously considering selling the 3 bikes n buying an old car to hotrod or something. Too much free time n shitty tv, and nothing to do playing with my head. lol. Determined not to strip ninja right down till bandits good as done, so been twiddling my thumbs last couple weeks. Thankfully I’ve come to my senses again and kicked myself back into gear today feeling a bit refreshed n an appetite for bikes again. Getting out n about on my Harris last few weeks has certainly helped fuel the 2 wheeled love affair again. Bloody freezing n wheelspinning everywhere, but good to get out n burn some rubber/fuel. lol

Got side panel repaired after my drill slip (Doh!). Invisible n good as new.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/BinditSidepanelrepair1.jpg

While sticking that back on I noticed the sidestand propped up on block of alloy. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/NewBinditSidestand1.jpg

Chopped it to right length on bike workbench, but when took down n got suspension set right the length was wrong. Even if length was ok the tiny stand footprint was a problem waiting to happen sinking into ground n dumping bike on its side. Was never happy with it n decided to pull my finger out n sort it today. Saw adjustable one in SF mag, but theyre waaaaaaaay expensive.

Dug out some offcuts from when made the handlebars and a length of thickwall alloy tube out of random box. No idea what its from, but seemed solid n bout right size I was after.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/NewBinditSidestand2.jpg

Chopped the original stand down n ground down edges to stick it in end of alloy tube. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/NewBinditSidestand3.jpg

Was going to make new top section, but would have meant lot of hours with my basic tooling, plus of course the side stand switch actuation and inherent strength of steel pivot over an alloy one. Saved lot of time n effort n strong. Diameters similar n flush fit so worked out well once slid together. Tapped couple holes to secure sections and a bolt for sidestand return spring locating. :-


http://i61.photobucket.com/albums/h63/pitstop-paint/NewBinditSidestand4.jpg

Made a swivel foot for the end with a little grub bolt tapped in to hold together but let pivot freely.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/NewBinditSidestand5.jpg

Cut it down foot n neatened it up a bit on lathe adding some chamfers to top edges n little recess, etc. Also cut few slots for a little grub screw to locate in to give me couple inches length adjustment if required.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/NewBinditSidestand6.jpg

Bolted on for a test fit.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/NewBinditSidestand7.jpg

Works fine and foot sits flat on ground, etc. Bike sits at better angle without blocks of alloy propping it up. Lol. Was going to turn the stand in lathe n removed the knurled sections, etc, but quite liking the shapes tbh so going to leave them as is.

I’ll get out tomorrow, remove it again, file the rough edges n sand n polish it up properly.

[Jon]

Got side stand cleaned up today. Hand file then rub over with 120 grit wet n dry, then 400 grit, then some Autosol metal polish n a buffing wheel on my £15 old granny drill. Came up like chrome which is cool. Few tiny marks, but nowt to lose any sleep over. Lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/binditstanddun1.jpg

All the bolts, etc at back n out of sight pretty much, keeping front sides on view clean.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditstanddun2.jpg

My wife asked me if I’d stolen a piston out of one of kids minimoto’s when she sae end foot bit of stand. Lol. Does kinda look like a tiny piston with that groove in it.

Went to bolt it on n wouldn’t line up with hole in top section. Cursed for minute or two, then realized I’d assembled the top section upside down in above pictures. Doh. Quick swap about n looks pretty good I reckon.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditstanddun3.jpg

Folds up fine like original. Pics a bit blurry as one hand holding camera n other holding bike.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditstanddun4.jpg

Wish the rest of bits would turn up in mail……

[Fight_fan]

Looks the goods Jon! N yeh I totally thought it looked a bit like a mini piston too...

[Jon]

Curved oil cooler n lines turned up today from Emoe. Many thanks. For grand cost of postage, which takes me up to £477 including bike so far.

Had a flat cooler already from Yantosh ages ago, but no lines so swapping to this one saves expense of lines/fittings n adaptors for sump, etc. I’ll use the other one for another project I’m sure. Always a handy thing to have sitting. Stainless scrap n old fireguard mesh cooler guard I made for other one swapped over to this cooler fine too with bit of bending. Result. Not gonna be seen on bike low down at front behind scoops/plumbing but will save a stone going through it. Most of single track mountain roads round here just loose shingle so stones a real problem. Looks alright tho.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newbinditcooler.jpg

Took rubber mounts off other cooler n checked it for fit on bike. Need to drill couple holes on oil cooler bracket that I made before, but that’s it. Lines good short length which will easily reach sump without having much excess length to route neatly. Checked one of hose adaptors to engine n screws straight into sump, so all I need to buy is couple copper washers n job done. Hopefully I can get em locally. I’ll get a look tomorrow.

Been waiting 3 weeks now for last few silicone bends n boost gauge to show up in mail. Contacted suppliers about it n they’re sending replacements out, so should have something to work with soon enough.

[Jon]

Had a go at fitting oil cooler tonight as got couple copper washers in local village for a hefty 10 pence each. Lol.

Shoved trike back n moved bike into middle of space so had bitta room to work with.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Binditcooleron1.jpg

Drilled couple new holes in bracket I already had and bolted it up. Gently bent the sump steel sections of lines to increase ground clearance as much as possible. Probably still only 3-4” clearance under there, but whole bikes pretty damn low. Not low enough to ground out on anything other than a pavement edge or speed bump though so not going to worry about it. Not many of either of those about anyway. I’ll be crawling over any big obstacles like that anyway. All bolted up tho.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Binditcooleron2.jpg

As I was tightening up last union while on my back on floor under bike, I tugged spanner too hard n pulled bike forward enough for side stand to fold! Got my arm out and slowed its fall (fucked my shoulder up as no leverage). Thankfully was only 6” or so fall as was right next to my Harris. Expected the worst, but escaped with only a tiny 5mm long little dint/scratch in side of seat panel. Barely shows in picture.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Binditcooleron3.jpg

Too deep to sand n polish out, so need to take seat unit off n sand/touch-up/re-clear it. Could try touching up on bike, but not sure how well that’ll work. PITA, but not something I cant sort. Just a few hours of pissin about. Could have been a lot worse for sure. Thankfully other bike was in way to break its fall or would’ve been real bad.

I’ll get the seat sorted next few evenings. I’m a mighty 33 year old tomorrow so probably wont be in garage in evening, but I’ll probably end up there anyway. Lol.

[Jon]

Well its been bout 3-odd weeks, but last parts finally turned up this evening. Not the parts I ordered, but replacements after 1st lot didn’t turn up and moaned at supplier. Sent me 4 silicone bends instead of 3 tho, and even though they’re black instead of blue like I ordered I’m not complaining too much. All come in handy plumbing everything in and black probably better buried away at front end anyway. Ordered 90 degree bends even though needing several 45 degree bends as way cheaper to get the 90 degree ones n chop em in half. Lol.

Gauge is little chav one that lights up in different colours, etc (was cheap). Shows negative boost too tho which will be handy for setting up dump valve.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN853305.jpg

Got to plumb n wire in boost gauge, and make a turned alloy housing of some sort for it to mount to bike as going to be visable. And of course a shitload of plumbing fabrication.

Also removed/sanded/touched up seat unit today so I’ll get that clear coated along with one of karting helmets I’m working on at moment and can get that back on too.

Plenty to do! Gonna be busy for next couple weeks of evenings. Moving in right direction tho instead of moaning I’m waiting on parts n have nothing to do in evenings. Lol.

[Jon]

Couple hours tonight freezin my arse off in garage. Lol. Made a housing for boost gauge out of small scraps of 60mm stainless pipe I had left over from exhausts. Cut it to a point to echo exhausts and clock housing shapes, etc. Mounted it pro-street style above clocks.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditboostgaugeon1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/binditboostgaugeon2.jpg

Sits at same angle as clocks/nose fairing so doesn’t look too outta place.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditboostgaugeon3.jpg

Shape covers opening underneath for air hose and cables to gauge which disappear downwards n not easily seen.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditboostgaugeon4.jpg

Swivels with forks as per clocks and clears nose fairing easily at full lock.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditboostgaugeon5.jpg

Lights up something like 7 different colours. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditboostgaugeon6.jpg

Any 1 of em will do for number of night-time miles I do. Put off night riding somewhat since hit that stag years back on ninja. Plus roads round here are lethal at night. 100`+ drops n no safety barriers or street lights. Sheep n big black and brown highland cows free roaming too. Bonkers.

Make a start on plumbing next few evenings hopefully. Got seat unit clear coated today too so can get that sanded/polished n back on somepoint.

Total inc. bike is now £517 including bits that arrived other day. Broke my £500 guesstimate, but that should be everything needed to complete build now. Not counting oil n petrol. Lol.

[Jon]

Been busy last few evenings doing some plumbing.

Company sent me an extra 90 degree silicone bend by mistake, so tore apart few bits on bike and replaced the washing machine pipe makeshift one on bottom of plenum. Probably stand up to radiant temperature from engine slightly better. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/turboplumbindun1.jpg

Cracked out the rest of silicone bends and aluminium scaffolding tube and finished off LHS connections. Plumbed in pitot tube, etc. Had enough jubilee clips for all this side so everything tightened up. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/turboplumbindun2.jpg

Managed to stab myself in finger with screwdriver doing up one of clamps, but was on a roll, so stuck some insulation tape round my finger n cracked on with front of bike. Got everything cut n slid into place. Ran out of clamps (few on way in mail from GixerJon) so all just push fit for now.

Kept it all tight underneath side scoops which hides a lot of it. Not immediately obvious when standing next to bike.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/turboplumbindun3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/turboplumbindun4.jpg

Need to bend right down on knees at front to really see the plumbing. Black silicone bends help out a lot tho. Could paint tubing black too I suppose, but seems fine as is.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/turboplumbindun5.jpg

As much mudguard/wheel clearance as exhaust headers, etc so should be fine. Can always raise front end slightly again if needs be.

Clips should come through mail some point this week so can clamp up front connections properly. I’ll grab a jerry can of petrol next time down the village and can plumb in fuel tank and try setup base fuel pressure. Going to have to find somewhere to get oil for engine too. Don’t think theres anywhere on island to get bike oil, so might have to Ebay some. One of the drawbacks of island life!

Bike did come with spare oil filter, but that was for B6 engine. Might be compatable tho. Water damaged box, but filter still plastic sealed, etc, so I’ll check the codes n see if usable. If not I’ll order one with the oil.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/turboplumbindun6.jpg

Know engine came out of running bike, and had recent full rebuild..Touched starter for 1 second today and motor spins over fine, sparks, and boost gauge registers couple psi of negative boost so promising signs.

Sanded back seat unit too, just need to buff it up n bolt it back on.

[Jon]

Seat unit polished up n bolted back on as good as new. Well better than new if new is factory finish. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/binditseatsorted.jpg

Checked online and bandit oil filter I have is right for this engine too (thanks Suzuki!), so that’s a bonus n few quid saved. Putting in an order to Germany or some work stock so get some oil added to that order n save delivery costs. Lol.

Been concerned about rear shock tbh. Just too softly sprung for bikes weight and extra leverage of longer swingarm. Very soft back end n worried about grounding out against seat as that low. Spotted a Busa shock on Egay on ½ price sale for bout £25-odd delivered! Snapped it up. Plan is swap it over for Srad one that’s in bike just now, which should be able to sell on for similar money n get a shock upgrade for nowt. Lol.

Be much better suited being rated for a 260kg wet bike weight rather than Srad’s 200kg. Should be simple enough bolt in too as similar shock shape and reservoir position, etc.

[Jon]

Jeez where to begin. Not been many forum posts or pictures of late as nothing much to show, but been piling in the hours of late sorting seemingly endless niggles and fuckin big problems. Listed em below for anyone bored n wanting a read. Lol. :-

1) – Electrics shorting out on side mount number plate. Wire to numberplate light rubbed through on pivot point so remade few bits n rewired whole thing to stop it happening again.

2) – Decided to check for spark at plugs as start-up not far off. No spark on any plug! FOOK! Spent whole weekend other week ripping ½ of bike apart trying to find problem.

Voltage to coils, coil resistance fine (even though was a running bike at start of build), stripped loom n double checked CDI connections from engine/cdi swap, ran over cdi with multimeter to make sure getting proper feed/earth, etc, swapped back to bandit cdi n wired that in, still nowt, stripped crank pick-up assembly on end of engine, still nowt, pulled apart ½ of loom to check connectors/dud wires which meant stripping large chunks of bike for access, still nowt. Eventually I checked HT leads into coils. Turns out the aftermarket Taylor leads were too big to fit into standard coil bodies properly sank good.o spark was having to jump ½” gap to get to leads! God knows how running beforehand. Pared them down n got em fitting into coil properly. 4 sparking plugs at last. Thank fook!

3) – Front brake splitter above mudguard wet with brake fluid. Stripped n trimmed back each hose n re-did connections. Bled back up, but still damp this morning so must be the copper washers in between all banjos on splitter. Never replaced em on assembly for some reason so me own fault. No biggy tho. Spend 50 pence on copper washers next week n re-bleed, etc n should be sorted out.

4) Got can of fuel to stick in tank. Poured it in n pissed out bottom! Fuel tap boss had a curve to it from when damaged. Only 1mm or so curvature in center between 2 tap bolts but enough for rubber tap seal not to work. Feck. Never noticed it n Yantosh welded up bottom of tank n we thought was fine. The thought of sending a fully airbrushed tank several hundred miles to Yantosh to cut n weld on new tap boss didn’t appeal from terms of cost/time n fookn up paintwork with cutting/welding heat, etc.

Found some hermetite petrol specific 2-part epoxy locally. Permanent repairs to fuel tanks n stuff. Used it years back on my trikes old steel tank n was still petrol proof 12 years later when binned steel tank for a spun alloy one so knew it was good stuff. Buzzed back to bare steel round tap n clamped up fuel tap with epoxy n place of rubber seal n sorted now thank fook!

5) Connected fuel pipes to n from tank today n packed between engine/carbs with rags before switched on ignition, expecting problems. Fuel returning to tank quickly n free of obstructions. No leaks from pump/regulator/hoses or anything so was well chuffed. Dialed in little bit of residual base pressure to carbs to maintain fuel flow to carbs under boost n everything was fine.

After about a minute or two of sitting with ignition/pump on though fuel started pissin out of 3 of 4 carbs. Thank god for rags. Lol. Was pissed off for minute or two thinking I’d fucked up somewhere or carbs had a problem. Thought it odd tho that not all carbs leaking so tapped each float bowl with wooden mallet n screwdriver few times thinking maybe a dry/stuck float from sitting as stripped carbs before installed em on engine. Next time I tried only had one carb leaking, so repeated it. Few taps later n no leaks at all. Wahey. Stuck battery charger on to stop battery running down n left ignition on and pump circulating fuel at few psi to carbs for good ½ hour. Came back n everything still bone dry so happy with that. Did try winding fuel pressure up good chunk way above what I’ll ever need (with the engine running) n still no leaks so looking well. Would have expected a leak at higher pressures with engine off, but nope.



Just waiting on engine oil n last jubilee clamps turning up in mail now, n can hit the starter button n take it from there really setting stuff up.

[Fight_fan]

Awesome news! Cnt wait to see it running! Vids will be required!

[Jon]

My bargain Busa shock finally turned up this afternoon after 2 weeks wainting! Ebay guy took 11 days to put it in a box n send it off. 2-3 days actual traveling time. Hey ho here now. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/busashock.jpg

Looks like a straight swap more or less. Fingers crossed anyway I don’t have to turn up new bushings on lathe, etc. It’ll go in one way or another anyway, even if have to make new dogbones up.

Also managed to get some copper washers for front brake line splitter.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/brakewashers.jpg

Not going to get near it much next few days as bogged down with airbrush work, but aiming to leave myself the weekend fully clear to sort front brake leak n cram that fat-ass Busa shock in there. That’s my good weekend planned. Lol.

Give it a damn good clean up next couple evenings tho as covered in chain crap, etc. Seems fine tho. Pretty clean under layer of slime. Lol.

[Jon]

Had a go at shock today while had a bit of time free. Busa shock on the bottom, Srad on top for comparison.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin1.jpg

Very similar. Fittings identical which saved lot of pissing about on lathe. Reservoirs slightly different shape, overall length bit different, etc, but not far off at all. Busa one just far chunkier. Spring is good ½ as thick again. I’ll stick srad one back on Egay. Be usefull to someone.

After lot of swearing n crushed fingers got it in there. Still need to clamp up my shock cover but jubilee clips were about 2mm too short to reach over bigger spring so need to get some bigger ones to clamp it up again.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin2.jpg

Access was a bitch to say the least. Had to chop down dogbones I made by inch or so and move holes by same. Not hellish amount to swap over though. Let bike down off jack and its spot on. Back end is solid as a rock now. Static sag about 2” lower than pics with my fat arse on it. Bike sits at better angle at back end, etc too. Much better.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin4.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin5.jpg

Set bike slightly higher than before to give plenty under seat clearance and bit more oil line clearance under sump as hangs down low.

http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin6.jpg

Pretty chuffed with that shock tho. Feels miles better, even just sat still in garage.

Noticed on full lock the yokes were just catching the front turbo plumbing n couple bits n bobs. Nothing bad, but wasn’t right if know what I mean. Drilled lock-stops on bottom yoke and put a little M5 allen bolt through. Gave me an adjustable setting by shimming with little 1mm washers. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin7.jpg

Not affected steering lock tbh. Reduced it very slightly, but still waaaay more than most sportsbikes and my Harris, etc.

Was on a roll so replaced front brake splitter washers n re-bled brakes. No annoying seeping of fluid now. One more thing ticked off list for £25 pence outlay..:-

http://i61.photobucket.com/albums/h63/pitstop-paint/busashockin8.jpg

Come on postman bring my jubilee clips and engine oil !!!

On a totally different topic I finally joined Facebook if anyones on there. My personal link is below if wanna say hello or send a friend request or owt. :-

http://www.facebook.com/pitstop.paint

Got a link to my business page on there. Not relying on facebook for advertising or owt, but all helps. Most folk will still go to my website. Mostly just on there to keep in touch with folk cos I’m a sod for not keeping in touch with people so handy tool.

[Jon]

Mixed bag of good n bad news today, but further forward than I was at least. Progress is progress

Engine oil arrived this afternoon. Filled up engine, hit the starter and fired straight up with no real effort. Expected a fight but straight off button. Switched off choke and adjusted tickover right down to normal setting. Adjusted dump valve so just fluttering at tickover and had a nice steady tickover. Left it sitting like that for a minute or two burbling away. Fairly loud, but not as loud as expected considering theres no baffling at all. Raspy but not any louder than my Harris or trike really.

Still waiting on jubilee clips for front turbo plumbing so everything just press fit at moment. GixerJon sent me another set of clips in mail though as 1st set went missing. PITA but some coming anyway so I can get everything clamped up. Couldn’t therefore test for boost really. Did touch throttle briefly n revs shot up like standard bike to bout 7K on rev counter. No hesitation at all. Didn’t glance at boost gauge, but revved fine whether building boost or not with everything not clamped up. That’s the good bit.

Bad bit is oil building up in exhaust side of turbo. Pulled off outlet pipework from turbo n couldn’t see any oil, but might have been blown on in airstream from turbo to carbs. Seems mostly exhaust side of turbo though. Can think of 5 reasons really.:-

1) – The turbo sitting at an angle of 20-odd degrees is causing turbo to back up with oil. Doubt this is the problem unless every blow thru bike spits out oil when left on tickover on sidestand. Can eliminate this by sticking front paddock stand on and raising front end to level out angle of turbo body. If the problem this will solve it n let me know I need to change turbo mounting angle to headers.

2) – Oil feed to turbo is too much. Banjo onto turbo has a 2.5mm passageway in it. Other people recommended 2mm being the maximum diameter without over oiling turbo with same turbo model and gixer engine. Could be a problem. Might be worth reducing to 2mm n seeing if helps cure it.

3) – Oil drain is restrictive n blocking up turbo. Drain line runs at a shallow angle back to clutch cover. Might be the cause. Drain line n fittings good 12-13mm bore though. Tbh don’t think this is the problem but worth considering. Not sure how to test if this is problem tho.

4) – Turbo oil seals are fooked n need a rebuild kit. Possible as was 2nd hand turbo. Negligable shaft movement tho.

5) – All the oil is coming from engine n nothing to do with turbo. Possibility, but unlikely as engine straight out of running healthy bike as owner upgraded to 1100 lump. Always the possibility of stuck piston oil ring tho. Could eliminate this by unbolting turbo from headers n run engine to see if coming out pipes.

That’s all I can think of for now. Suppose best place to start is trying number 1 as that will eliminate turbo angle and also increase drain line angle to clutch cover eliminating number 3 from my list. If that don’t solve it try numbers 2 and 5. That will leave only number 4 as a possibility.

So yeah problems, but pretty happy overall. Good to hear it run and it’s a definite step forwards despite the problems.

[Deano]

Just disconnect ang turbo drain pipe work and let it drain out of the turbo into a bucket and see if it still has issues

[Jon]

YEah gonna try oil drain into a tub, then lift back up to same angle as connects to engine n see if slows/backs up. That'll isolate drain issues. I imagine its somewhere in oil feed pressure/drain angles, but process of elimination really.

[Jon]

Went to start it again yesterday afternoon to poke about a bit n outta fuel. Doh! lol. Probably why it conked out on me other day while running fine. Went down to local garage and armed myself with 2 jerry cans of fuel, some spare oil to top-up as go, and I cleared myself work wise for weekend to should get a bit of troubleshooting done over weekend n narrow down problem. That was the plan anyway…………..

Hurt my back real bad last weekend, but of course been working like a twat all week n made it serious. Bad night last night n got up this morning and cant even breath right without muscle spasms n practically blacking out with pain. Cant sit, cant lie down, hell cant even put my own socks on. Docs on monday as its something real serious. Same sorta intense pain as when I shattered my shoulder blade into 10 peices n had bone fragments stuck in nerves/tendons. :(

PITA as had organised free weekend time wise, stocked up on petrol/oil for bike, and I'm 98% sure I know what the main oil problem is n how to solve it.

Oil feed banjo to turbo has 2.5mm restrictor built in. Looked about through old threads on OSS forum n most folk are running 1.5mm oil line restrictor bore to same turbo. Doesnt sound much 1mm, but at high psi it is. lol. Working it into cross sectional area of the feed pipe (flow), the turbos getting practically 3x the oil it needs. Would explain it spittin it out. Just cant do sod all about it with this back. Bored shitless and cant go further than kettle, even then it’s a lot of pain. Pissed off. Cant even sit n draw or airbrush.

[Fight_fan]

Not good mate, I hope u get urself sorted out ASAP!

[Jon]

Well my backs still damn painful, but good enough to hobble about like a little old man at least. On the mend.

Went out this afternoon after spraying n stuck the petrol I bought in tank, etc. Thought the problem was over oiling the turbo with the oil feed only having a 2.5mm restriction built into banjo. After talking to Emoe about it n spending time over weekend looking through old OSS forum posts, etc I whipped off banjo bolt to take it down to my local garage to get the passageway brazed up so could re-drill it at somewhere in region of 1 – 1.5mm as per other peoples setups. Only then did I realize the passageway may be 2.5mm, but the actual hole feeding the banjo bolt from the banjo is a single 1mm hole. Bought the banjo n bolt from a Japanese tuning company specifically for this model turbo, so already setup. Doh!

Thought right if its not over oiling then it’s a draining issue. Removed drain hose from fitting on clutch cover so could start up bike n drain into a container n see if shallow angle of hose was the issue. As I pulled off the hose (bike on sidestand) oil pissed out. WTF I thought.

Slightly embarrassing this, but yeah I am human at end of the day n I can admit my fookups. Somewhere between sore back n lack of mobility during week n excitement to start up bike I’d overfilled the bike. Lol. Oil couldn’t drain from turbo as oil level was above fitting. Feel like a prat, but shit happens. Oil was that damn clean n same colour as backplate in clutch cover with poor shed 60W lightbulb lighting n inability to bend down.

Drained off a bit of oil (a largish bit I’ll admit) n brought a torch out to the garage so could actually see sight glass window properly, n filled to right level.lol.

Stuck key in but battery too flat to fire it up n just turned slowly n flooded engine. Battery charger on now. Waiting on some power in battery n a dry-ish engine. Hopefully fire it up later tonight or tomorrow afternoon when got fiddling time n see if cured oil problem.

[Jon]

Finished spraying a helmet for Canada pretty early on in afternoon today which was unexpected so ran out to garage. Lol

Fired it up n still smoking the same unfortunately! Since for once I had daylight, I shifted trike, etc n rolled bike out onto my driveway.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup01.jpg

Took a few pics as makes a change to be able to walk around it instead of cramped up in garage.

http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup02.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup03.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup04.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup05.jpg

Driveways on fair slope as you can see in pics so thought maybe it was the turbos angle on headers of 20-30-odd degrees that was causing drain issues. Fired it up n still the same. Wasn’t quite level even on driveway slope though.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup06.jpg

Set up a shaky dodgy ramp setup on driveway n carefully sat n rode front end up ramp to gain another foot at least under front wheel. Didn’t make any difference to oil coming out at all.

Removed drain hose from clutch cover and ran it into a container perfectly vertical. Again no change at all from its normal shallow angle. Flow doesn’t change at all when hose is raised back to normal angle. Steady trickle filling maybe ½ the pipes bore at tickover. Not a drain issue as far as I can see from these tests, n know feed is ok.

Shot some video to show the smoking. It’s a bit naff, but had to upload it on dial-up so pretty limited. Lol. Loud enough to hear from other side of island, so about right for me. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/th_Smokeystartupturbobandit.jpg (http://s61.photobucket.com/albums/h63/pitstop-paint/?action=view&current=Smokeystartupturbobandit.mp4)

Oil leaks on tickover n builds up eventually in exhaust housing. Smoking way worse when revved up as yer can see. No turbo expert, but thought turbo should seal better when revved due to increased oil pressure on seals from higher oil pressure n rotational forces, etc.?? Unless of course seals are guffed and it’ll blow oil like a bitch when revs rise, which looks like my problem.

Also ruled out crankcase pressure by running disconnected drain hose and running without oil filler cap. Ruled out oil coming from engine as had plugs in n out few times n nowt but fuel on em when flooded it. Also forced open turbo’s blow off valve manually n no big stream of oil coming from engine or anything, just exhaust gases.

I’ve ran out of anything to test now! Only thing I can think of that’s left is the turbo’s oil seals. Bit of a pisser as no dosh for em right now. Know mates that can talk me though rebuilding turbo though.

On plus side though, starts off button every time, ticks over fine, rev’s fine, drove it up driveway n into garage n felt fine. Can hear turbo spooling up when rev it n spooling down again when shut throttle. No nasty noises or owt, just a nice whine (might be able to hear it in video if turn it right up). Headers not leaking. Blow off valve flutters on tickover n shuts when revved. Still waiting on pipework clamps, but shows bit of boost on gauge when revved n rev’s clean right to redline. Cant even think about setting up boost levels n pissin about with pitot tube, etc till get handle on oil tho as spitting it out all over me n the bike. Lol. Cleaning can wait tho.

Couple pics of some ugly twat sitting on it to give idea of size. Pretty small given I’m a midget at only 5` 8” or so. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup07.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/banditstartup08.jpg

[Gix11]

2 things:
1. She looks so much better out in the open when you get the full perspective. That's one intimidating looking bike mate. 2. Where you live looks like one chilled out place mate. Do much fishing?

[Jon]

Yeah pretty damn quiet up here. :D

As for fishing, not me personally. Must be the only person up here without an interest in it tbh. Spent years n years working in various fish/prawn/shellfish factorys doing 16 hour shifts filleting the stuff, then many more years working in seafood restaurant cooking the stuff. Wee bit sick of it.:D:D:D

Get random 80 year old guys walking past n dropping in odd fish now n again though. Quick fillet n yum![:p]

[Jon]

Gixerjon was struggling to get his boss to let him `borrow` some jubilee clips, so no worries. Cheers for trying bud.

Was up town today n spotted some nice chunky clips in a farming store of all places n at a decent price too. Spent pretty much bang on £10 give or take few pence n got (8x) 65mm clips for remainder of up-pipe plumbing at front of bike, and also (2x) humungous clips to clamp up the stainless rear shock cover that’s still sitting loose on Busa shock. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Pileoclips.jpg

Got pipework clamps on tonight, n I’ll shift the trike out of garage tomorrow n get shock cover ones on. Summit to do. Lol.

Turbo rebuild kits are about the £50-odd mark delivered which seems fair enough tbh. They come with all seals/bearings n new clips, etc like below.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Turbokit.jpg

Hopefully cutting a bit of a biker barter with a mate (ya know who yer are) in exchange for some spraying/caricature or something, to get kit for me. Been reading up every article on rebuilding these turbos online. Found some really good websites that show you literally step by step how to do it with pictures, and how to mark it all up so doesn’t need rebalancing when done. Doesn’t look too hard really. Surprisingly few parts inside turbos. Lol. Just slow n steady n fiddly job by looks of it. As long as slow n methodical then should be straight forwards enough. New skill for me to learn. I like learning new stuff so fine with me. Doesn’t really require many specialist tools neither.

Was routing through pics of my turbo when first got it to find serial numbers, etc to ensure get right seal kit, n came across pictures before cleaned it up.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Oilytubby.jpg

Oil seepage from back of exhaust turbine is sure sign of seals gone from what I’ve read. Didn’t know that at time though, just thought it was oil from stripping it out of car. Hey ho live n learn. Turbo seems fine apart from seals, but going to strip right down n replace all the bearings, etc anyway to be sure its sound.

I’ll stick up some pics when comes to rebuilding it. Not much I can do in meantime till get rebuild kit though apart from general tinkering.

[Bastard]

dont know if its the same as yours mate but at £50 buy it now & £15 delivery might be of interest

http://cgi.ebay.co.uk/car-parts-saab-900-9-3-turbo-charger-/320658576418?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item4aa8bd9422

[Jon]

Just gonna rebuild ebuild kit is only £50-odd delivered n includes all bearings n seal. Central shaft seems ok n both impeller wheels unmarked too. Seems fine barring oil seals, but going to do whole lot while in there anyway. Kits quite comprehensive.

[Jon]

Bit of biker barter swapsies. Doing a caricature of a mates wee one n his minimoto in exchange for turbo rebuild kit with new bearings/seals, etc. On the way in the mail. Woohoo.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Turbokitegay.jpg

Should get rid of shaft play and James Bond smoke screen action. Done a chunk of research online into rebuilding the turbo n doesn’t look too hard, so see how I get on.

[Jon]

Rebuild kit arrived at weekend, but not even opened packet as yet. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/TubbyRebuildKitEre.jpg

Wanted to get it `paid for` as such by doing the caricature I swapped in `biker barter` for it. Been doing that last few evenings. Wee man’s 1st Birthday very soon so though bit young to appreciate it as yet will make nice addition to his wall. Wee man n his minimoto.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/HaydenColour-web.jpg
.
Next few evenings are gonna be spent taking turbo off bike n stripping it down. Mates got some big-ass circlip pliers which will make life easier as snapped 2 sets of normal long-nose pliers last time taking the big circlip off. Lol.

Using these sites as a guide if anyones going through similar thing. Might help someone out.:-

http://www.sr20forum.com/turbo-guides/254779-how-rebuild-t25-t28-turbo.html
http://www.driftworks.com/forum/technical/60665-how-rebuild-your-t28-turbo.html
http://photo.platonoff.com/Auto/20051009.Garrett_T25_Turbo_Rebuild/

Also came across this exploded drawing of a dynamic seal T25 Garrett if any use to anyone?:-

http://i61.photobucket.com/albums/h63/pitstop-paint/T25Turboschematic.jpg

[Jon]

Been busy last few evenings after spraying. Only an hour or so here n there as work airbrushing/spraying is mad busy at moment.

Marked each of 3 segments of turbo up to keep my clocking/port alignment right when goes back on bike.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild01.jpg

Also marked up nut/intake turbine/shaft alignment to keep turbos inherent balance correct on reassembly. Not got anywhere nearby that can re-balance turbo for me n certainly not the money for it. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild02.jpg

Got everything apart eventually. Few rusty bolts/clips, the usual. Shaft exhaust turbine fins had tiny little nicks here n there where free play in turbo must have lead to it touching housing slightly. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild03.jpg

After conferring with few turbo guys a lot more knowledgeable than me I opted to keep it rather than replace. Not got another £75 for new shaft assembly plus balancing money, etc. Not bad damage n will maybe drop my efficiency by couple percent if that so not end of world.

Started taiking bearings out, etc to find central cartridge was packed (and I mean packed!) with burnt crusty oil sludge. Cant have been helping unit drain properly at all as half passageways clogged up with it. Scooped out enough to fill half a mug easy. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild04.jpg

Main bearings n thrust bearing out n they were fooked! Good 1mm play in thrust bearing n main bearings real slack on turbine shaft. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild05.jpg

Degreased every part n cleaned out insides with airgun, etc getting everything spotless inside. Took hours, but worth the time spent. Everything layed out ready for re-assembly along with rebuild kit parts, etc. Pile of junk parts to top right of photo.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild06.jpg

Centre cartridge almost done with new bearings n thrust bearing n seal clips, etc, etc. All nice n clean with no play anywhere.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild07.jpg
Was flying along at this point n finding it easy going tbh. Then of course it went tits up. Lol. Couldn’t get turbine shaft back into finished assembly. Sealing clip needed to compress as slid down this angled hole into central body of turbo. Due to scores though from slack in turbo before tho it wouldn’t damn go in. Spent bout 2 evenings trying to get it in to no avail!:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild08.jpg

Eventually had to resort to stripping out turbo body again, masking it off n cleaning up surface with my dremmel n tiny polishing stone to remove scores. Sealing edge couple mm below this edge so not interfering with anything. That done n still had problems, but got there eventually through perseverance n making various tools out of old allen keys ground down to gentle assist in compressing sealing ring manually n slipping shaft right down into body. Many hours spent for 30-second job. Lol.

Got turbo back together this evening.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Tubbyrebuild09.jpg

Tested dump valve with my mini-airbrush compressor connected to airline on turbo. Compressors had nice accurate gauge so could test valve n actuators action. Adjusted so starts to open at 6 psi or so n fully open at 7-8 psi. Just sets it up roughly in right region to get me going with once on bike.

That was meant to be it for today, but couldn’t resist running out to garage n bolting it all back together! Out tomorrow all day with family/car so thought sod it I neeeeeeeeed to know. Lol.

Bolted it together n video below shows results. Starts up piece of piss as yer can see. No oil at tickover or anything unlike before. Little bit of oil vapour when really revved, but nothing serious n burns off in pipe rather than pissing out all over me/the bike/the floor. Bit of an improvement! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/th_Rebuiltturbostart.jpg (http://s61.photobucket.com/albums/h63/pitstop-paint/?action=view&current=Rebuiltturbostart.mp4)

Going to drag trike, etc out of way over weekend when get the chance n take bike outside. Stick it on a slope like before n run drain into a bucket, etc and see if makes any difference to last of oil vapour coming out. Doubt it, but worth trying just to fine tune it as such if can. Pretty happy with difference though already. Spins up fine n not dripping oil out everywhere like before. Bikes revving cleanly. Don’t know about boosting, but not far off being able to take up n down road outside house n seeing whats what boost/fueling wise n take it from there really.

[JDinOZ]

Awesome man! make sure to bring a camera :)

[Jon]

Finished up spraying at reasonable hour today n evenings are drawing out a bit, etc so still had daylight. Been itching to get bike out on road n see whats what. Kicked my hearse, trike, couple compressors, etc out of way n dragged bandit out of shed.

Battery was practically dead n turned over very slowly, but fired straight up first touch of button anyway surprisingly. Felt hard to roll out of shed n down drive even though down fair slope, but thought it was just some rust on discs that would soon clean off when moving. Ha!

Grabbed me lid. Oil on ground from my hearse no bike. Lol. Been fixing oil leak/brakes/power steering,etc. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Bindit1strun1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Bindit1strun2.jpg

Went up road outside house in 1st gear n just about binned it as front end all over shop n weaving violently, and wanting to tuck in on itself, etc. Stopped n went to turn around n couldn’t move it without getting off n shoving damn hard. Walking pace back to me shed n one of front calipers/discs hot. Gave it a clean out from sitting about not being used.

Back up road n felt lot better obviously. Lol. Not much room to stretch its legs on these roads, but did whang open throttle once on a straightish bit of single track shingle road. After wheel span sideways it revved to redline fine with no flatspots. Couldn’t tell if boosting as my cheap gauge seems to be bin-fodder. Jumps about doing sod all then resets itself at 20 psi at tickover. Lol. Need to keep my eye out for a decent cheap glycerin filled proper one on egay. Felt A LOT quicker than any 750 I’ve ever ridden though so reckon its boosting at least some. Way quicker than my ninja which pumps out similar power to standard 750 lump and is way way lighter. I’ve ridden zzr’s, blackbirds n early busa’s, etc n feels comparable.

Noticed couple of things when got back to shed though.:-

1) Sidestand at lowest setting, but needs chopped down a bit as bike sits dangerously upright on stand. Seems right length in shed but have a shallow in garage floor where bike sits. Lol.

2) Front end still a bit twitchy. Feels like steering angle too steep. Think back end needs dropped down couple inches to match lowness of front. Not a big job, but will sort it out easy enough.

3) Chopped too much off dump valve spring as too soft now. Not closing fully when rev bike right up so loosing some boost pressure there for sure. Can soon make up a wee spacer to increase spring pre-load again tho.

4) Extra length on swingarm seems to take lot of weight off front end. Was wheelspinning n locking up back wheel on brake seriously easily. Something to get used to. Lol.

5) Exhaust oil smoke doesn’t seem to be an issue when moving. Only smokes when get up to at least 9-10K revs. Not badly though to bother me. No smoke at normal riding revs. Turbo definitely a lot healthier. Can hear it spinning down nicely when rev n let go of throttle. Even when sitting on tickover n hit kill switch it you can watch turbine down exhaust n takes good 10 seconds to stop turning after engines off.

6) Surprisingly turbo being outboard to side of bike seems balanced fine by intercooler on other side. No real unbalance n felt fine round the corners. Not had a chance to really roadtest it tho. Good enough handling for a predominantly straight line machine anyway.


So yeah pretty happy with first test run. Few bits to do, etc but no biggy. Good to finally move under its own power as such rather than being a noisy ornament that I work on every day. Lol. Feels mad as fook being so wide going up the road as nice n hunched riding position what with narrow straight handlebars, etc. Get these bits n bobs done n then see about getting its MOT test n getting it on the road, etc. My MOT station is 100 mile round trip from my house, so good test run.

[Fight_fan]

Result!!! Good shit mate, best of luck with MoT

[Jon]

New boost gauge arrived today. Fluid filled accurate gauge which should stop it flickering about all over the place like other one. £6.50 off Egay which aint bad even by my cheap-ass standards. Lol. Other one going back on that site to cover cost of this one.

Much bigger diameter than other gauge and bottom outlet for hose means theres no way its going to fit on like old one. Still want it above clocks though.

On the plus side though I had a spare compressor hose fitting with same thread as gauge which gives me a good secure fixing for hose. I also found after a bit of tinkering that I didn’t have any stainless/alloy tube big enough, but an old rattle-can spray lid fitted perfectly over back of gauge behind chrome bezel, n tidies it up a bit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeere1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeere2.jpg

Can easily spray the cap to match the rest of paintwork, and a basic bracket will mount it on in roughly same place as old one.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeere3.jpg

Not quite as swoopy as old housing, but should look neat enough. Get that all sorted n bolted up next few days.

Also lowered back end of bike last week by 2” or so. Racked up good 50+ miles up n down road outside house and all handling n braking as it should, etc now. Just feels like normal bike really.

Photographer Simon Everett is up here next month to photo it for `Streetfighters` magazine according to MDM so better get it cleaned up, etc somepoint as alloy all white n furry from winter months. Lol.

[Jon]

New boost gauge arrived today. Fluid filled accurate gauge which should stop it flickering about all over the place like other one. £6.50 off Egay which aint bad even by my cheap-ass standards. Lol. Other one going back on that site to cover cost of this one.

Much bigger diameter than other gauge and bottom outlet for hose means theres no way its going to fit on like old one. Still want it above clocks though.

On the plus side though I had a spare compressor hose fitting with same thread as gauge which gives me a good secure fixing for hose. I also found after a bit of tinkering that I didn’t have any stainless/alloy tube big enough, but an old rattle-can spray lid fitted perfectly over back of gauge behind chrome bezel, n tidies it up a bit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeere1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeere2.jpg

Can easily spray the cap to match the rest of paintwork, and a basic bracket will mount it on in roughly same place as old one.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeere3.jpg

Not quite as swoopy as old housing, but should look neat enough. Get that all sorted n bolted up next few days.

Also lowered back end of bike last week by 2” or so. Racked up good 50+ miles up n down road outside house and all handling n braking as it should, etc now. Just feels like normal bike really.

Photographer Simon Everett is up here next month to photo it for `Streetfighters` magazine according to MDM so better get it cleaned up, etc somepoint as alloy all white n furry from winter months. Lol.

[Jon]

Rattle can lid sprayed up.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeon1.jpg

Simple 2mm alloy bracket n all mounted up.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/newboostgaugeon2.jpg

Looks alright. Not as swoopy as old setup, but gauge much more accurate and easier to read too.

Loads of bits I still want to do on the bike n take apart n re-make. Fit few new bits n bobs, etc, etc. Photographer from Streetfighters mag due up here this month though so leaving as is for now tbh. Give it a damn good wash n polish up next semi-decent afternoon we get as storm weather here just now. Get it all blinged up for photos before I go near it again with oily hands n spanners. Lol.

[Jon]

Sat outside in sunshine all yesterday afternoon scrubbing away removing oily hand prints, metal swarf and general smeg. Loads of sheep shit from going up n down road outside my house too. Lol. Good proper clean and polish n all sitting ready for the photographer. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Ready4photoshoot6.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Ready4photoshoot7.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Ready4photoshoot8.jpg

Updated n fitted new spec sheet on back of flip down numberplate thing. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Ready4photoshoot9.jpg

Basically just cleaned crap out of it to make it as good as can be for pictures. Get photo session out of the way then start proper setting things up boost wise n lots of road testing, etc. Muwahahahaha…………

Side-on shot showing the lowered back end. Only couple of inches but made all the difference to the handling n reckon its sitting better now tbh too.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Ready4photoshoot1.jpg

[Jon]

Not touched bike for about a month now tbh. Had my head down between busy airbrushing workload and working on my daily driver hearse every evening and weekend giving it a good sorting out mechanically.

Didn’t want to touch the bike till Streetfighters magazine photographer had been. His dates for coming up turned out to be completely different to what we’d initially thought though. He’s not due up this way till July or even August. Im not sitting on my arse for that long waiting, so sod it time to get the bike covered in oily handprints again. Lol

Want to get it boosting right, etc. Had a cylinder 3 filling up with fuel on and off lately and after tapping the float bowl I decided I had to whip carbs off and see what was what. Also getting boost leaking out round the plenum when boost starts to build.

Took the lot apart this afternoon in between clear coating helmets. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/plenumoff2805111.jpg

Stripped carbs and turned out to be a tiny bit of dirt in cylinder 3’s carb just stopping fuel cut-off valve from seating right. Cleaned out all 4 carbs anyway to be sure. Ordered up a cheap inline filter off Egay for the fuel line to stop any more crap coming through into carbs. I’ll mount it before the fuel pump when gets here.

The plenum I’ve never been 100% happy with. I did my best with junk metal and a stick welder, but it was never right. The plenum ports and carb mouths didn’t align quite right and overall it was a bit shit. Took it off and threw it in junk pile! Chopped back silicone hoses and clamped them up tight on carbs ready for new plenum. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/plenumoff2805112.jpg

The only bit of the old plenum I kept was the air hose fitting off the top. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/plenumoff2805113.jpg

Measured up the carb port spacing accurately with micrometer this time rather than a ruler with half the lines worn off. Probably a bit more accurate. 10 mins on google sketchup and got a good idea and dimensions needed. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/plenumoff2805114.jpg

I was going to order up some more steel and cut out the parts and jig it all up accurately and then pay someone with better welding gear locally to weld it properly for me. My mate Emoe (Hayden cycles) though is needing some paintwork doing and just so happens to be a bit handy at engineering. Lol. He’s going to make up a nice posh Tig welded alloy plenum for me which will be super accurate and line up with carbs 100% right. No more boost leaking for me hopefully. Miles better than what I can make with equipment I have so pretty excited about it tbh.

Also ordered up this £9 delivered inline fuel pressure gauge as the scrap one I plumbed in originally turned out to be a dud. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/plenumoff2805115.jpg

Should allow me to set up the fuelling nice n accurately statically, and see whats happening when builds boost with new plenum on.

[Deano]

Teething problems. Got to love them. You need to get it fully sorted before it gets featured in a mag cause it just isn't right having bikes that look "finished" in the mag but truth be known they don't hardly ride. I now they probably do it heaps but any dickhead can throw a turbo on a bike make it look good and claim stupid outputs just to make themselves look good.
And I also think anyone that "claims" a hp figure should have a dyno chart to back it up if they want the figures published

Good luck with the build

[Jon]

Yeah I was holding off on doing anything to bike because I thought photographer was imminant and didnt want him turning up and me sitting there with bike in bits. I'm not finished the bike by any means, and probably never will be. lol

Ultimately I want to get my hands on a B12 motor and bigger turbo and run a reliable 200bhp or so at wheel long term. I know a lot more is possible, but I want to be able to ride this thing long distance touring 2-up with luggage so want it tractable and reliable really.

At moment though moneys tight, so get 750 lump running right on boost and live with that for a while. More power than I can use on loose gravel single track mountain roads round here anyway. :D Most of bits I've made will swap straight over to bigger engine down the line thanks to Suzuki interchangability, so Im working on the principle of get everything right at this stage so in a good position later on. I'm 33 years old so got about 7 years till hit my official midlife crisis age.:D

Know what you mean about some of the magazine feature bikes though bud. Was just talking about it with my wife yesterday looking at some recent custom bike events where the bikes dont even run or have electrics or engine internals. Kinda pointless when some of bikes must have 50K+ of parts put into them. Everyones different though I guess. Seems daft to me personally though having that much cash invested in an ornament though.

Hear what yer saying about bhp levels too. See some of em in mags that claim 400-500+, when in reality when switch back to normal low octane unleaded gas from the high street gas pump, and are forced to lower boost then its a different story. End of the day though theyre just stating the capability of theyre machines outright with no limitations, etc.

[Jon]

New plenum in the mail somewhere on way to me. Exciting stuff!

Emoe (Haydencycles) made it for me in exchange for sorting out his tank paintwork for him. We opted to make it out of steel to ensure accuracy during welding and he had some suitable material for main body sitting in workshop. Also went with a rectangular section as he had some suitable box section in stock as I say, and looking at dimensions it gave me more clearance on the bike around the plenum, and a greater internal volume too which should ensure pitot tube pressurization of carbs works correctly. Also easier to machine/clamp up for welding more accurately than round body, so just better for both of us really.

Have to say although Emoe’s a friend I really rate his work. Top stuff. He sent me some pics of the process. Thought I’d post them up for folk that are interested in the mechanical porn side of things. I’m no engineer, but love these sort of pics of folk doing what they do with theyre skills. Puts my engineering skill set to shame.

The 4 inlet stubs and up-pipe connection from turbo feature turned ends on the lathe to ensure positive location to main body during welding. Neat.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild01.jpg

Main body holes chopped out with super accurate port spacing on CNC mill.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild02.jpg

Heres a close up of the little lip on the ends so everything lined up 100% before any welding even.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild03.jpg

Quick tap n everything in place for welding with no chance of moving about.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild04.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild05.jpg

Out with the Tig.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild06.jpg

Kinda puts my stick welding to shame. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild07.jpg

Ends getting tacked on.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild08.jpg

Getting there, just pressure takeoff point n up-pipe connection to go.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild09.jpg

Threaded insert being welded on for my hose fitting to feed carbs/pressure regulator, etc.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild10.jpg

Up-pipe on n all finished. Looin forwards to getting it in mail.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild11.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/EmoePlenumBuild12.jpg

Give it a lick of paint when here and get it bolted on, n take it from there really with the bike. Should be free of pressure leaks n building boost n ready to run n setup. Insurance set up for the bike so hopefully not far off the road now got this vital piece sorted out professionally.

[Jon]

Mail came this afternoon.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0208111.jpg

Ran out after airbrushing and mixture of good n bad really. Good thing is ports are bang on and lines up perfectly to the mm.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0208112.jpg

From the side it fits comfortably in space too.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0208113.jpg

Then went to slip it into silicone joiners to carbs n wouldn’t sodding fit. Im stronger than average person but even straining away like a constipated guy on a toilet I couldn’t get more than 2 ports in more than 5mm. The problem is the carbs are 58mm so when clamped up tight I’ve not got enough joiner length to slip in the plenum ends. Basically the silicone joiners are too short and need to be the length of this scrap bit in picture. Bout double the length of old plenum joins. Balls! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0208114.jpg

Hey ho not end of the world. Going to order up some more silicone tubing. Gives me a few days to primer/paint up the plenum a nice blue, cut down couple of sections of up-pipe to suit new plenum location and get few other odds n ends sorted. Not held me back as such. Few days n should be able to hit the starter again.

Fook me though. Having not worked on the bike for few weeks I lifted the cover today and just stood there thinking `Jesus that things mad as fook`. Lol. Funny how perceptions change when not seeing it every day.

[Jon]

Held of spraying plenum last couple of days. Didn’t want to spray it then find up-pipe tube needed cut or brackets welded on, etc. I was also contemplating welding on brackets to add some tie-bars to head to hold plenum onto carbs under boost.

New silicone tube came in today’s mail. Had just finished the artwork karting helmet so had couple hours free to head for the man-cave (garage).

Chopped the 250mm into 4 equal lengths. Didn’t want to cut it too short first try. Bolted them to carbs, slipped on new plenum.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0508111.jpg

Test fit of side panels though wasn’t good. Too much of a gap to frame.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0508112.jpg

Kept trimming off small 5mm widths till it sat better.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0508113.jpg

Perfect port alignment and fits in there nicely.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0508114.jpg

Slipped 90 degree bend onto bottom of plenum and fits in space and lines up fine ready to reconnect plumbing.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0508115.jpg

Test fit of side panels and seat better this time. Slight gap but less than was there before with old plenum and nothing worth worrying about.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0508116.jpg

As for adding tie-bars, etc I’ve decided not to tbh. Plenum is feckin solid onto carbs and that’s without the clamps on! Cant physically pull the plenum off by hand, the rubber sticks that well to the longish plenum stubs. Nice snug tight fit. When connect up up-pipe connection, etc the plenums held pretty damn solid on there. Only running low boost so I’m confident it wont go anywhere.

About to primer and spray the plenum blue tonight. Only clear coating customer airbrushing tomorrow so should be able to get plenum back on and reconnect all the hoses/fuel lines, stick bodywork back on, etc this weekend, as taking Sunday off (worked last 4 or 5). Aiming to get the base fuel pressure setup to 3-4 psi once back in one piece, hit the starter and see if from there. Hopefully be building boost this weekend. If not then I’m a damn sight closer to it.

[Jon]

Worked every weekend for last month or two, but had this weekend mostly off work so it was MANCAVE time!

In between clear coating a customer lid yesterday I got bike back together after painting plenum metallic blue on friday night.

Everything plumbed in and side panels on, etc.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0708111.jpg

Switched on ignition, fuel system refilled after 10 seconds or so, then set base fuel pressure to 3.5psi over boost level.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0708112.jpg

Hit the starter and…………………………..nothing much. Starter groaned over very slowly. Sodding battery flat. Lol. Hooked the charger up and sat clock watching out the corner of my eye for few hours waiting to push that button.

Battery charged and I fired it up Saturday night. Sodding smoke everywhere (and I mean everywhere) and crawled my way to garage door to find huge mushroom cloud above garage. Lol. Went back in and carb number 3 again was pissin out fuel at the bottom of the float bowl and also flooding the cylinder which raised the oil level in the crankcase with excess petrol cutting off the drainage for the turbo, hence pissing it out the exhaust.

Went into the house last night a bit pissed off tbh, but after thinking the problem out and speaking to few mates and folk on OSS I knew where problem was.

Fuel float heights in carbs needs to be adjusted for turbo use to compensate for higher baseline fuel pressure in carbs with turbo use. Took bike apart this morning and cleaned out the carbs :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0708113.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0708114.jpg

Quite a bit of crap in there considering I cleaned em out few weeks back but that was before inline fuel filter was added. I also changed the placement of the inline filter to after the fuel pump and before the regulator like advised by a helpful guy on OSS.

Got carb heights set at 16.5, about 2mm larger than 14.6 measurement of stock which means 2mm lower fuel height in carbs when flip carbs right way up.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit0708115.jpg

Bike back together and no fuel leaks out bottom of carbs, no fuel going into oil again as far as I can tell as oil level didnt change after running it. Started off the button each time, rev's fine, etc. Tickover fine, etc, etc. Also lowered base fuel pressure to 2psi.

Still getting some smoke out of turbo slightly but oils contaminated so much thinner. Plus when look through sight glass on clutch cover the petrol contamination is foaming up, etc n prob blocking draining slightly. Wee bit of petrol coming out of oil breather too but again understandable as petrol foaming n condensing in breather tank. Change of oil should cure both probs. Going to try get oil tomorrow at next village and flush/refill. If not its an order online job yet again. One of the hassles of living in middle of nowhere.

Wasn’t building boost though and I was really discouraged tbh as felt like I was close after a whole weekend at it.

A very knowledgable guy on OSS did inform me however that it would’nt actually show boost unless under load (i.e. on the road). Was speaking to Emoe (Haydencycles) online and he was telling me his old 680bhp Subaru impreza running 50 psi would only build 1 or 2 psi of boost in neutral gear max.

Emoe gave me a prod n said to go try it and phone text him afterwards to see how it went. Lol. Dug out bike and tried it on the road. Bear in mind the only bit of straight road I have round here is about 100 yards long single track with a blind bend over a blind crest each end.

Wound it up in first gear wheel spinning everywhere on loose shingle road and glanced down to see couple psi on boost gauge. Had another run at it other way n saw 3-odd psi before I had to lock up front end on gravel road before went off the bend/hill at other end. Didnt get right up rev range, or gears but enough to see its boosting. Was fairly shifting on such a small road anyway and just about missed the corner. Fair drop at edge too. Lol. So yeah building boost. Confident if get bigger bit of road it'll be hitting peak torque of 7psi. Had plenty more to go by feel of it.

Revved clean onto boost with no stumble at all. Just built revs like normal but quicker. Nice and smooth with no carb hiccups or owt. Was well chuffed when got back.

During the week Im going to weld up a brace to support back end of bike and strap it down to ground so I can run it in gear safely. Stick in higher gear and wind on slowly applying some back brake to load it and try set boost limit close as I can, then its road testing really. Insured as of couple days ago as swapped insurance over from my ninja project bike thats getting sold on completion. Get it up town for an mot, etc.

Long weekend at it but paid off with that one little test run. Well happy here. [8D][8D][8D]

[Yella]

I need to read this thread again. Nice work great to see a result

[Jon]

Yer pretty chuffed bud. Going to get some fresh oil in and start setting boost level up, etc. Running fine though and silky smooth onto boost so everything looking good.

[Dynomutt]

I wouldn't try loading it up using the rear brake as you intend, apart from the likelyhood of burning your rear disc out, and boiling brake fluid, if you start trying to drag the rear brake the rear suspension will start to try and compress, which will make the whole thing vibrate about. The last thing you need is the bike shaking itself over whilst it is running the rear wheel at 50+mph as it starts to make boost or snapping the chain. You need to either get it to a dyno (not easy given your location) or ride it on the road whilst you adjust the boost, you won't replicate the correct conditions trying to drag the brake. Rear discs will heat up very quickly, I had one glowing bright red on a bike I ran on my dyno because the brake was dragging slightly because of corroded pistons, two runs of less than 80mph had the thing almost transparent with heat, the disc cracked as it cooled down. It would be much safer to try a straight piece of road somewhere, preferably uphill slightly, and load it that way

[Jon]

quote:Originally posted by Dynomutt

I wouldn't try loading it up using the rear brake as you intend, apart from the likelyhood of burning your rear disc out, and boiling brake fluid, if you start trying to drag the rear brake the rear suspension will start to try and compress, which will make the whole thing vibrate about. The last thing you need is the bike shaking itself over whilst it is running the rear wheel at 50+mph as it starts to make boost or snapping the chain. You need to either get it to a dyno (not easy given your location) or ride it on the road whilst you adjust the boost, you won't replicate the correct conditions trying to drag the brake. Rear discs will heat up very quickly, I had one glowing bright red on a bike I ran on my dyno because the brake was dragging slightly because of corroded pistons, two runs of less than 80mph had the thing almost transparent with heat, the disc cracked as it cooled down. It would be much safer to try a straight piece of road somewhere, preferably uphill slightly, and load it that way


That was my worry too bud. Everyones telling me to do it this way though. Tbh though I'd rather just ride it as know whats ging to happen more accurately doing that. Know its boosting and running/riding fine. Everything works, etc. Set wastegate manually with compressor and accurate gauge to be fully open for 7psi so know its fairly close. Will need some adjustment Im sure in riding conditions, but know its not going to overboost or anything. I'll probably just book mot test n ride it tbh. Seems safer to me anyway.

[el sammo]

fantastic man, impressed with the way your going about this build!! awesome

[Jon]

quote:Originally posted by el sammo

fantastic man, impressed with the way your going about this build!! awesome


Thanks bud. Im doing best I can with limited tooling n cash. Biggest problems Ive faced have been just down to my location tbh. PITA to get anything up here on this island. Every time you need a hose clip its onto Egay and wait a week.:D

Saying that though it will make it all the more sweet when bike hits the road as theres nothing remotely like it on the island. Next to no modified bike at all excpt bolt on stuff tbh. Ive got the only trike on the osland too. My Harris stands out like a sore thumb at bike meets as so different, so god knows what they'll make of the bandit. :D

[thewiz]

farking awesome job man i would love to make shit and air brush like you i tried to get two letters air brushed on my tank and it was $400 for 2 letters so i had to get stickers made your air brushing is amazing just like you bike .

[Jon]

quote:Originally posted by thewiz

farking awesome job man i would love to make shit and air brush like you i tried to get two letters air brushed on my tank and it was $400 for 2 letters so i had to get stickers made your air brushing is amazing just like you bike .


Cheers bud. Dont know what $400 australian dollars equates to in £ but sounds expensive for basic artwork. Some folk do charge a lot though to make a decent living at it.

I make burger flipper wages tbh, but I do love what I do and enjoy creating artwork and the feedback I get. Also get flexible hours and no boss berating me, etc, etc. Plus of course I can live in middle of nowhere.:D Pretty much outweighs lack of income. Sort of learn to make do with less cash after a while. Tbh I never used to make anything and used to buy things out of catalogues for my bikes when had normal job. Reduced income though means Ive learnt to make things from scratch cheaply. Cant be a bad thing as I enjoy it and end up with something different. Good hobby bike building.[8D]

[Jon]

Got some oil locally. They only had 3ltr, but luckily had an unopened 1ltr at home. Engine fired up first touch of button and even the choke worked normally as it sat there on tickover warming up. Didn’t expect everything to be so user friendly standard bike-ish from cold. Not complaining though as will make bike easier to live with.

Flushed out contaminated oil, put in new stuff. Couple hundred ml of old stuff kicking around in passageways and in filter, etc but nothing to worry about. Fired it up again and smoking out of turbo problem is back to normal. Very slight mist in air like it was before. Nothing to worry about. Can live with very slight smoke now n again. It’s virtually nothing though again so that’s that problem sorted.

Went round bike sorting few odds n sods and checking nothing worked loose anywhere. Sodding little pin on back brake lever at pivot to master cylinder has vanished in test run other day. Only held in with crappy split-pin so must have pinged out on road somewhere. Hey ho replaced it with decent bolt and nyloc nut.

I chipped petrol cap at weekend when dropped a spanner out of my mouth ( twat, I know, I know). Whipped that off. I also caught the end wheel on my lathe with boost gauge cowl too when putting bike away at weekend (double twat). Only took an hour to sand/paint/clearcoat the two pieces though so no problem. Just wanting the wee bits right before I’m too busy riding to polish. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit1008111.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit1008112.jpg

Went to fire it up next day and fired up fine then dropped to 3 cylinders, to 2 cylinders then cut out. Couldn’t hear normal `old man peeing` trickle of petrol return into tank from pump neither. Bugger a problem, then opened tank and realized I was outta petrol. Does tend to help. Lol. Grabbed couple jerry cans from village today though.

I’m away in the next few days on a ferry over to the mainland with my trike for its mot, but early next week I’m going to make time to get the bike out for some further testing now I’m caught up with work, etc. Some nice sunny evenings at the moment to take advantage of. The bridge/causeway linking my island to main island is 5 minutes away, and is almost ¼ mile long, die straight new tarmac with good visibility both ends and dual lane too so bit more space to open it up safely.. Perfect for testing purposes. lol

[thewiz]

iv started making thing for my bike because i dont have the money to buy them and its fun.
here are the 2 letters i wanted air brush .

http://i260.photobucket.com/albums/ii21/Mullman2000/MoreFish/DSCF4079.jpg

[Jon]

$400 AUS = £254 GBP according to online conversion. If had to repair dents, paint it black, do the airbrushing, and clearcoat whole thing, then sand/polish whole lot to show standards then thats about right tbh at going rates.

If just putting on lettering over existing paint n throwing on couple coats of clear then I'd expect it to be cheaper by my costings. Depends on artist and quality of theyre work though realistically. Some guys are dirt cheap, and some are £800 GBP to paint a helmet. Need to balance out quality vs. cost same as anything.

[thewiz]

there are no dents in the tank i just had it painted at the french polishing shop.

[Jon]

Got new plugs through post. Just put em in. WOW. What a difference. First touch of button startup, hot starts fine now too unlike before. Crisp throttle and oil mist out of turbo reduced even more. Must have been some unburnt fuel in cyclinders too. Holding throttle at 1/2 revs even theres next to sod all coming out of exhaust and I'll be riding at below that most of time. Sorted. Revved bike a lot and ran it in shed for 10 mins. When turned off there was a very light film of oil on inside of exhaust and that was it. Sort of a greasy food finger residue on surface (i.e. sod all). No black oil like before so well chuffed with that.

Tickover jumped up to 2500 revs tho. lol. Wound out adjuster on side of carbs but not making much difference. Took carbs off several times and fitted a stronger return spring, etc but no difference. On about the 4th stripdown I found the problem. Carb balance adjusters miles out so cylinders 1&2 had theyre butterflys open by 0.5mm or so at tickover therefore raising revs. Balanced carbs by hand using gaps trick. I’ll borrow vacuum gauges when get a chance, but tickover rock solid at 1000 rpm or so, so not far off.

Started it bout 20 times though when out there n firing up straight off button hot or cold. Also wound out idle mixture screws some 6 turns over stock to richen it up on tickover after reading setup tips on OSS. Firing up lot easier as a result so deffo helped.

TEST RUN…………

Sunny-ish this afternoon after work. Few damp patches n puddles about but not too bad compared to storms of last few days. Wasn’t about to waste opportunity.

Took it a few miles to the bridge/causeway as only straight bit of open tarmac for miles. Opened it up and built to 3psi of boost by 1/3 revs or so real easy and smooth. Wouldn’t go beyond that though. Sat rock steady at about 3psi from less than ½ revs to max revs. Slight flat spot in carburetion when tried to build boost in too high a gear at like 30mph but pulls through it. Flat spot not noticeable though if in right gear. Just wanted to see what it would do if tried it. Lol.

I set the wastegate up originally very roughly when was rebuilding the turbo using my airbrush compressor to get it opening early and being fully open at 7 psi roughly. Obviously that doesn’t equate once up n running due to pressure drop through intercooler n all the pipework, etc. Looks like I need to wind the wastegate adjuster out couple turns at a time till hitting my 7psi of boost. Building boost at low revs easy though so no reason to doubt it. Bit of adjustment is all really.

Other than that engines running at ok temp, no leaks. Bit fookin loud till get up the gears a bit. Might make up some small baffle plates to stick in exhaust to take the edge off it.

Apart from that its all fine. Front brakes surprisingly good compared to 1st generation bandits, but bit bigger piston size. Bike came with brand new discs and sintered pads though which probably helps. Lol. Back brake kinda useless due to length of swingarm as no weight on it. Locks up real easy!

Handles alright too. Cant throw it around like my Harris, but not too bad. Just a slight adjustment of riding style really. Rides fine. Got my Harris there for corner carving anyway as bandits a straight line tool.

Some of looks I got off folk on pavement and in cars coming other way was classic. Don’t think they knew what to think. Just sort of stood there with jaws open. Lol.

Gradual upping of boost is all really. Going to brace up numberplate bracket a bit to make it a bit stronger as flexed a fair bit when got up to speed. Apart from that really though I think I’m ready for booking MOT n getting some miles in. Carry a spanner with me till got boost level set right. ;D

[Dynomutt]

You really need to increase the size of the pilot jets, the pilot mixture screws have no real influence once they go over about 3.5 turns out, as the tapered portion of the screw is completely out of the pilot mixture orifice. I'd go up by one size and see how that feels.

[Jon]

quote:Originally posted by Dynomutt

You really need to increase the size of the pilot jets, the pilot mixture screws have no real influence once they go over about 3.5 turns out, as the tapered portion of the screw is completely out of the pilot mixture orifice. I'd go up by one size and see how that feels.


I'll look into that cheers. Tbh was starting and ticking over fine at standard settings. Was an article on it on OSS forced induction section and they recommended 8 turns out as opposed to standard 2 turns. Didnt make a huge difference to mine but seemed to help slightly.

[Dynomutt]

The other way of richening the circuit is to reduce the size of the airjet, the old Ledar kits used to use air correction jets to reduce the airjet sizes, mainly the main airjets to richen the circuit but retain the stock needle profiles rather than increasing the mainjet and then using a new needle profile to sort the part throttle fueling as Dynojet tend to, but it would be easier for you to go up a size on the pilot jet which would then allow the pilot mixture screws to be put back in to around 2.0 to 2.5 turns out and retain the range of adjustability. I quite often need to increase the pilot jet size on some bikes when I'm setting them up on my dyno, especially when using carbs from a smaller machine like GSXR750 oilcooled 38mm on an 1100 or larger motor. TBH I wouldn't have expected the pilots to need increasing on your combo, but if the pilot mixture screws are having to be wound right out like that then a size increase is the only real option.

[Jon]

Well had my photoshoot on Thursday. Just around about my house same as last few features. Stunning scenery so handy as a backdrop.

Took about 2 hours to get the photos taken, but the sun came out as soon as Simon Everett arrived and started raining as soon as he left so got lucky with the weather. Big thanks to Claire for doing the modeling for me. Poor lass was frozen solid by time we got done. She hadn’t done bike photoshoots before, as done clothes/catalogues/tv work before, but tried her best and the photos should look good I reckon as did a lot of poses n angles with her and bike and bike on its own, etc. Only one or two riding shots with me on it thankfully as I hate being in front of camera. Besides Claire is a lot better looking than me on the bike. Lol.

Getting some photos on cd of the photoshoot, so I’ll stick up a couple of pics on here when get the ok from MDM. He might want to hold them back till feature comes out, but might be able to stick up a couple teaser photos before then for you all. Failing that you’ll all have to keep buying Streetfighters magazine and wait for the feature. Lol.

Going to book the mot as soon as I can and get her on the road properly. All insured and ready to go though. Turned the boost up couple of turns the other day and running/boosting fine at moment. Just need some road space to stretch its legs a bit. Run up town to mot station will be good test run though.

[Gix11]

This is going to be a rad feature bike mate. Looking forward to getting the mag! Cheers for a great topic Jon.

[Jon]

quote:Originally posted by Gix11

This is going to be a rad feature bike mate. Looking forward to getting the mag! Cheers for a great topic Jon.


No probs bud. Like I've said on other forums the build diary online has been great for me. Kept me focussed on the project and moving forwards with it all. If Id stopped half way through I would have got hounded by people to pull my finger out. lol. As it was had people emailing me all the time asking for updates, etc so kept me going with it even when Id lost motivation.

Typing up what Id done kept me focussed on the project and what I was doing next, etc. Worked for me anyway.[8D]

[Gitzy]

Great Feature Jon, It was a great read Mate.. Claire looked the goods too :p

http://img27.imageshack.us/img27/4631/jonsa.jpg

[Jon]

Cheers Gitzy.:cool:

Got CD of the photoshoot pics through from Will yesterday. Some good ones on it. I'll stick some up on my website next update.

Dropping cd of pics into Claire tomorrow too as she's excited to see them and wants copy for her folio, etc.

Also dropping a copy into the original owner who hasnt really seen it since I bought it off him in various boxes.:D He followed the build loosly on OSS, but not seen finished article as yet. I'll drop round his house with the bike if weather ever improves. Been blowing gales n raining up here for weeks on end.:(

[Jon]

Not updated for a while. Things have been stressfull here so slipped out of order of importance tbh.

Terminal illness in family to deal with which has been ripping my family to bits last 6 months or so. Add on top of that straight 70+ hour weeks with commission work n just couldn’t find motivation to build/update about what Im doing.

Been trying to spend less time in garage and more time indoors to see us through it so progress has been slow.

Chopped it about fair bit. Liked Viz`s turbo chop thingy layout n decided to go similar route.

In pieces again.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods01.jpg

Carefuly split open end clamp with hammer n screwdriver. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods02.jpg

Flipped one end round and closed it up again.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods03.jpg

Made a bracket to mount oil cooler up top, and new bracket to mount intercooler down bottom of front. Bit of tube shows where new Yantosh header log manifold will fit between the two. Intercooler is several inches narrower than oil cooler so wont grind on tarmac like cooler guard did when leant over. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods04.jpg

Got busy with grinder and hand file, etc and made this chunky alloy bracket to support dump valve.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods05.jpg

New LHS layout of plumbing.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods06.jpg

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods07.jpg

My mate Steve up town found a engineering place that made oil lines for boats, etc. They chopped about my original oil lines and used the ends, etc off them to make new ones cheaply. Sump ends were modified to sit much closer to engine too for more ground clearance.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods08.jpg

Steve also scored these for free. 90 degree adaptors for cooler end of hoses.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods09.jpg

New front layout.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods10.jpg

Little carbon fibre cover made out of section of and old damaged hugger. Covers rusty ugliness of turbo centre section a bit.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods11.jpg

Where turbo will sit on new headers. Yantosh is making endplate adjustable/clamp on so turbo will be swiveled to dead level instead of at angle like before. Should get rid of last of smoking.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods12.jpg

Pipe exit into intercooler. Had to clock turbo body parts again to get it to line up.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods13.jpg

Turbo tight against engine now so mucho narrower. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods14.jpg
Top view to give an idea. Bout same width as bars. Only 3” wider than Z lump in my Harris. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods15.jpg

Few pics with turbo stood on axle stand where it`ll be going.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods16.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods17.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods18.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods19.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods20.jpg

Left over parts. Not generally good to have parts left over but happy about it in this case. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods21.jpg

Just waiting on Mr. Yantosh having some spare time to make new headers up for it. Tig welded stainless loveliness with some sort of billet end swivel/clamp trickery. Lol

Also on the hunt for a B12 engine for it. A mate up town is building a hard up choppers wormburner chop. Stripped fair few bits off a cheap B12 he picked up for it. Decided he really wants a gsxr11 engine in it though so breaking the rest of B12. We`re discussing painting his chop in exchange for the B12 engine n carbs. Hopefully will come off. A mate Peter was running a B12/T25 combo successfully and kindly gave me his jetting setup, etc so could all work out well. See what happens.

[Gix11]

Shit, sorry to hear the bad news mate. Keep your spirits up and enjoy what you can with them.

As for the build, amazed you've had time, but you've streamlined her heaps mate. Looks good.

Viz's chop build was bloody great hey? On such a small budget he has grin factor 10!

If Yan is making some new headers it'll be worth the wait from what I have seen.

Good on ya Jon, and thanks for getting back with the updates mate, even with all the shit going on.

[Jon]

Hi bud. Yeah updating wasnt really high on my list of priorities tbh. I`ll try keep on top of threads though if can. Life has way of getting in way of best layed plans.

Yeah streamlined it a lot. Liked Viz`s layout so changed mine to suit. Once had everything in place I decided the scoops didnt work for me any more so binned em. Good few hours work in the scrap pile, but thats the way it goes sometimes. :D Just loved the way the pipework on LHS wrapped round the engine casing so left it uncovered. Not that wide at all now.

Hopefully Yan will have some spare time soonish to make headers for me. As mentioned Im chasing a B12 lump too so fingers crossed. Thats the long term goal anyway so if came off now and local it would be cool. See what happens really.

[Gix11]

I've only just worked out where you are mate! I saw the turn off for Skye when I was travelling around up there years ago. Visited Eilean Donan castle in kyle of lochalsh as I was a big Highlander fan. So you're just off the other side of Skye. Beautiful area mate, although I reckon winter would be fun!

[Jon]

Used to stay in Kyle of Lochalsh and on Skye for good 10 years or so till moved here 5 years ago. lol. Winters interesting yeah. :) Lots of candles and sandwich supplies for powercuts. lol. Like it here though. Farrrr away from civilisation and good empty biking roads.

[Gix11]

How big is the island? ...like how long to do a lap on the bike?

[Jon]

Is pretty sizeable tbh. Bit bigger than Skye. Take good couple of hours to get from bottom end to top as road follows line of mountains, etc so pretty winding. Few loops and loads of side roads too.