The Ranga Bike gets some upgrades

[Rocket]

After a hit and miss race season in Mod Bike at Kwinana with the BLOWN12 turbo GSXR1216, I decided that I'd had enough of carbies for a while and would do a few mods to the orange K1 GSXR1000 so it can be used for my track bike for the next season.

Now that I've got my black K6 back for a road bike and most of my bits have turned up, I can make a start.

I'd used the orange bike a few times for ANDRA rounds when the other one was playing up but with a sit up riding position and my fat arse, it was never going to be quick.


http://i114.photobucket.com/albums/n249/blowngsxr11/40thwesternationals56march2011112-1.jpg

So, with my garage having been run over by an excavator a few months back, Rock Hard kindly offered me some workshop space and his expert assistance to get this thing started.

http://i114.photobucket.com/albums/n249/blowngsxr11/rangaturbo001.jpg

First up was to fit some swingarm extensions to help tame the bike's tendency to wheelie through the first few gears, which is fun but makes my times embarrassingly slow.

These are 4" to 6" extensions I got from the net and they fit nicely.
I'll need to look for a long brake line but that should be easy.

I put these in first so we could measure up to order a long chain and a bigger back spocket.


The combination of the two should get the bike out of the hole a bit quicker and get me some respectable 1/4 mile times.

http://i114.photobucket.com/albums/n249/blowngsxr11/rangaturbo005.jpg
http://i114.photobucket.com/albums/n249/blowngsxr11/rangaturbo006.jpg



Oh, fucken hello !!




http://i114.photobucket.com/albums/n249/blowngsxr11/rangaturbo002.jpg

I ordered a turbo kit from Jack Frost at Holeshot Racing.
True to form, it took a while to be sent out, when it got here, some of the bits were missing, and when THEY got here, one of them doesnt fit properly.
Anyway, it'll all work out in the end. He does know his shit but it's a bit frustrating.

http://i114.photobucket.com/albums/n249/blowngsxr11/rangaturbo004.jpg

This system is going to run at 7psi which should be 230odd hp. At 15psi boost it should punch out 320 odd but I will need pistons and rods in it first. Maybe next season.
For the moment, it's just a special cometic head gasket and adjustable cam sprockets.
I'll slip in a new timing chain and adjuster as well for extra comfort.

http://i114.photobucket.com/albums/n249/blowngsxr11/rangaturbo003.jpg

So, Mozz was keen to drop the motor in order to make it easy for him to set up cam timing after the head goes back on. So out she came.
Not a big job and with this being the first modern bike donk I've taken out, I was surprised at how light it is.

http://i114.photobucket.com/albums/n249/blowngsxr11/rangaturbo007.jpg

Here's the motor, ready to have the head off when Mozz gets the inclination. Cam sprocks are at least a week away yet so there's not a massive rush.

http://i114.photobucket.com/albums/n249/blowngsxr11/Perth-20111016-00058.jpg

Next thing is to start looking for places to mount the extra guages without being too intrusive.

Morry is trying to convince me to go to clip ons but I'm resisting so far.
There's plenty of other goodies to go on but I'll keep them secret until they get fitted in order to keep this thread interesting without resorting to tits.

[Gitzy]

You don't Fck about do you Phill, love your work looks awesome..

[BANDITROD]

Fuck yeah rocket that's the go mate

[Gix11]

Into it already mate! Love your work.

[Pab13]

You guys always keep things interesting over there, great work by the way

[Large]

Got any Monsters left?

[Rocket]

Only in his pants.

[rock hard]

Here the engine is up on the chopping block.
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo004.jpg
the pointy sump needs a good wooden cradle
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo003.jpg
Head off cleaned up the chambers cant lap the valves.thats the problem with Titanium..
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo012.jpg
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo013.jpg
replaced the stock .7mm head gasket with a 2.5mm Cometic to drop the compression
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo016.jpg
tention the head and slip a new camchain in..just waiting for some adjustable cam sprockets to dial the cams..
As a mechanic i just Love Suzuki engines they are well built and straight forward to work on and service! Rockets buke has about 30k on the clock..bores look like new..it just needs 2 exhaust valve shims the other 14 were spot on..
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo008.jpg

[Rocket]

Awesome !
Word on the street is that the new sprockets will be here Monday or Tuesday.

[rock hard]

Got out in the shed today fitted up the actautor
with a little fiddling..i was suprised how much weight hangs off the exhaust studs..still a million little jobs to do..
so Rocket get your finger out!!!
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo018.jpg
http://i488.photobucket.com/albums/rr249/rockhard_photos/rangaturbo019.jpg

[BANDITROD]

Good stuff men

[rock hard]

Cam timing is done..now just button the top and side covers up engine back in the frame and over to you Rocket its time to get all that stuff bolted on..940941942943944

[fimpBIKES]

Boner time!!!

[mr.zxr]

The bike looks sweet. interesting to see what kind of times you get out of it.

[Rocket]

The plan is that when Mozzy gets back from the bush next, we'll slot the motor in the frame and it can finally come back to my place as I now have somewhere to keep it and I can start putting it back together and fitting all the bits and pieces to it like the lock up clutch, boost controller, shifter etc etc.
At this time, I'm sure we won't have it ready for this season so I'll be using the road bike with extensions for the next few meetings.
Hopefully it'll be all ready for after the winter.

[rock hard]

Extentions,you told me you were all natural..ha ha
yeah Rocket its going to be a big week, your motor,prep Bullfrog and WESTERN NATIONALS..do i sound excited...FUCK YEAH..im pumped..see ya when i get home mate..."let the sledging begin"

[Rocket]

I can't believe it's so long since I posted anything on this topic.
Which of course, means, I haven't done a great deal of late.

But with the race seacon coming up in a few months, I'd better pull finger !!

I got the bike back home a couple of months back from Rockhard's house so I could make a start on it.

I've had a few issues with bits not fitting properly with the turbo kit I got for it but I can work through most of those things.

A month or so back, I fitted this lock up clutch from MTC.
Looks very nice, hopefuly it works good too !
I also had to get a new clutch cover because of the extra width.

http://i114.photobucket.com/albums/n249/blowngsxr11/IMG_0075.jpg

I've had some issues with oil lines not being long enough and being wrong, I'm also missing some adaptors to fit the new injectors into the throttle bodies, but they're being sent now along with a missing fitting.
Turns out this oil line IS the right one.
Apparently I have it on the wrong side. Easy fixed.

http://i114.photobucket.com/albums/n249/blowngsxr11/IMG_0065.jpg

So today, while I'm waiting on the injector and fuel line bits, I fitted up a longer brake line and bled all the that up.
Then changed the sprockets on the bike so the front is now down by one and the rear is up by three.
I ran this gearing on the N/A K6 1000 last season and that was getting into fifth gear so hopefully this gearing will let me use all of fifth and maybe even some of sixth.
Had a cnt of a time getting the front sprocket undone.
My 18v Ryobi rattle gun wouldnt touch it and with the step daughter with a breaker bar leaning on the rear brack pedal, and me with a breaker bar trying to undo the nut, it was just not gunna work.
So I had to go borrow Rockhards air rattle gun and with a bit of work, it finally came free.
Now I just have to find what the fuck I did with the chain I took off the K6 at the end of last season and I can re-use that.

http://i114.photobucket.com/albums/n249/blowngsxr11/IMG_0076.jpg

My progress is being hampered a bit by my new house having fck all decent lighting in the shed so I can fiddle with it at night.
All I can do at the moment is try and find time and motivation on the weekends to do stuff to it.
But I am going to get some lighting sorted soon, even temporary lighting so I can start on it after work during the week instead of sitting on my fat arse in front of the tele.

[BANDITROD]

looking good phil will be good to see it finished

[MattyDucati]

Good stuff bloke, should be fun at the lights

[Gix11]

Nice one Phill. I'm amazed you have any time with a new house mate. Good on ya.

[Bob]

Looking good mate.

[Rocket]

Nice one Phill. I'm amazed you have any time with a new house mate. Good on ya.

Too right, Si.
With daytime on the weekends being the only time I can work on it until I get some lighting in the garage, it's hard to find time between driving around buying house shit, keeping the missus happy and coming up with good reasons why I can't do that fucking garden today.

But since I found out Big Brother is coming back on the TV, I'm actively on the hunt for lighting options.

[Rocket]

Just fiddled around with some bits today, reconnecting plugs and fiddly shit.
I need to get started on cutting out some brackets for gauge mounts so its time to crank up my new plasma cutter and make one sheet of ally plate into shit loads of little scrap pieces of aluminium to put in the bin.

Also found the chain I used on the temporarily extended K6 last season so I fitted that up.
I poked the back wheel out the back as far as I could while still allowing for some adjustment but the chain already stretched a bit when on the K6 so won't get much longer. I only had to take two links out of it to get it down to this length.
I'll flip those adjuster plates over to shorten up the adjuster bolts when I take the wheel out to get the Shinko fitted.
http://i114.photobucket.com/albums/n249/blowngsxr11/IMG_0082.jpg

That tyre is the result of a short 1st gear skid on very course bitumen.
Not only fucked the tyre but covered Wee Scottish Chris and his triumph with rubber ! Good times !

http://i114.photobucket.com/albums/n249/blowngsxr11/york2011004.jpg

[MattyDucati]

gettin close too racing phil?

[Rocket]

Not really Matty.
Still waiting on some parts to come from o/s.

Should be up and running for October when the season starts though.
Hopefully.

[Rocket]

Well bugger me ! Some parts arrived !
I finally got the injector adaptors that had been holding me up for so long, although I didnt get all the bits I was supposed to, but I'm used to that now.

So there's been a minor flurry of activity in the last week since the adaptors turned up.

With the adaptors fitted, I needed to drill holes into the throttle bodies to accept them. Pic below is prior to drilling.

2579

I also needed to drill out the the plastic bizzo's on the fuel rail a few mm to accept the larger tail end of the injector and o-ring.
I was a little concerned about the reduced thickness of the plastic handling the 50psi fuel pressure but I think it'll be fine.
I wont know till I plug it in and turn it on.

2580

With that done and the new plugs fitted to accept the new injectors, the throttle bodies were bolted back on.
2581

Next I moved onto the air shifter.
I started making brackets to accept the shifter onto the shift linkage but decided to get the one from MPS which looked so much better than anything I could come up with.
2582

I fitted the air bottle onto the tail and used one of the holes I made for the nitrous lines when I first built the bike to run the air line into the tail to the solenoid.

2583

At this point, Rockhard turned up and was itching to play with something, so he was kind enough to come and wire in the ignition cut out and the whole thing will operate from the horn button.

Next up is the e-boost2 controller.
This will allow me to run different amounts of boost in each gear with up to six different boost settings.
There's tons of options on how these things can control boost as well as other things they can operate, but I'm just using basic switching.
Rockhard also wired this in for me and it'll be set that when the horn button is pressed for each gear change, it'll step up to the next boost level setting.

2584

The boost control solenoid has been moved from here and the wiring tidied up (sorta) after Mozz wired it all in for me.

2578

Next thing was the tubing to the boost controller and to the intake manifold for the boost control valve.

2585

I've just started fitting up the plenum and pipework and with a minor tweak here and there of the piping from the snail, it'll be all good.
2586

The list of things left over is down to...

1, Complete fitting up the intake pipework
2, Fit oil lines. I have the oil feed line, I need to make the return line back to the sump with some fittings I have, some braided line, Billywhizz's welding skills and a drill and tap into the sump.
3, Find a K&N air filter that will fit.
4, Set up the fuel system with the fuel pump and rising rate regulator i have which I'm palnning to mount under the tank onto the fancy adaptor plate Ben Shaw made for me.
5, Get a breather set up for the crankcase breather.
I could probably fit a filter breather but should probably have a catch can.

Hopefully I will get most , if not all of these done this weekend.
Season starts here late October.
If I can get it running, then I can get tech inspected.
Then dyno.
Then do skids.

I have momentum and the panic of the seaon opener in just over a month.
Things are happening.

[BANDITROD]

fuck yeah phill looking good mate

[Rocket]

Couple of achievments today.
I managed to get the oil feed line fitted to the turbo.
Got the turbo pipe work on and connected up.
Sump drilled and tapped and awaiting fittings to be cut and shut tomorrow morning by BW.
Doesnt sound much but when shit doesnt fit properly, it can make a small job into a slow process.

Fitting shown below. One will be 45 degree out of the turbo, the other will be 90 degree off the sump, joined by the hose shown.
Got a new sump gasket today so i can bolt all of that up tomorrow and call that bit finished.
2588

Just a pic of the air shifter press guage for no good reason.

2589

Decided I should get some additional protection to ensure security.
I'm sure she'll get scary lookin' as she gets bigger.
2590

Tomorrow I will concentrate on gettin the oil return done, find a crankcase breather and see if i can get the fuel system mounted up.

If I imagine real hard, I might even be able to make smoke tomorrow.

Why are my pics small?
This new version of forum software is not liking me.

[hyofighter]

looking good rocket

[Rocket]

It's alive !!!
Hadto upload a map manually as the bigger injectors wouldnt allow the bike to run.
So we copied a map for a turbo R1 which has it running well enough for a lap around the block.
Poor running wasnt helped by the injector plug with a pin that had dropped out, but all good now.

I've tested the air shifter as well and that works great.

I'm still waiting on a breather bottle to arrive so I bodged up a line and filter for test rides.
Once the bottle arrives, I can hook that up and it's ready for ANDRA tech inspection.
Also needs to get some time on the dyno to get the tune right and set up the boost controller to change boost with each gear change.

Here's a wee vid.
I can't get this shit to embed for some reason.

http://www.youtube.com/watch?v=BU8bTamWhE8&feature=youtu.be

[rock hard]

good on ya Rocket you have done a shitload of work in the last couple of weeks..now to the dyno..shit we are gonna have some fun this season!!!

[ozzy1100]

you wa boys make me sick pricks lol

[LKC73]

Thats fucking awesome! Love your work mate and it looks like a lot of fun there.

[Surt]

me likes as well rocket and the progress looks fast

[BANDITROD]

fuck yeah phil thats shit hot mate

[Pab13]

Great work to all the W.A boys

[Rocket]

Finally got this girl onto the dyno, made just over 215hp with about 7.5 psi boost.
There's a bit left in it with a bit more timing adjustment and more dyno time but this is just fine to start with.
The big injectors are hardly breaking a sweat and the turbo can support 15psi so the 325 odd mark seems achievable if I go with rods and pistons later.

Here's an interesting vid of what happens behind the clutch cover at speed.
Nice flames at the end too.

Unfortunately there'll be no chance to get laps on the bike before the next race meeting so the funny car round on 29th December is its first outing.

Thanks to Brett Ghedina who fitted the powermod ignition piggyback system, helped with the final sorting and did the tune.

Can someone embed this for me?

http://m.youtube.com/?reload=5&rdm=mfca6b6fa#/watch?v=7J1e6QeCp2M

[MattyDucati]

nice, love the windage from the clutch:D

[MONO]

DONE and DONE


http://www.youtube.com/watch?v=7J1e6QeCp2M

[rock hard]

:rolleyes: much goodness

[BANDITROD]

thats fucking cool phil good job mate

[MattyDucati]

Hey Phill, its was good to see the ranga in the flesh on the weekend and to meet ya. When ya got into 2nd that thing was haulin! I think i seen a 8.64 from ya? very nice champ with more in the bank.

Watch you guys has givin me the drag bug again, already been looking at new zx14's for the strip :)

[Rocket]

Wow ! Thread revival !

Good to catch up too, I spotted the ASF shirt earlier on in the pits but couldn't stop to say gidday. Glad you came and found me.

Best on the weekend was an 8.71 which was pretty awesome, previous PB 8.98 but generally was producing 9.1s and the odd 9.0.
Still a bit of time left in the clutch and I still have a few psi of boost to wind into first gear, depending on the limits of the slick.
The wheelie bar proved to be a great investment, giving me three tenths improvement in the first meeting !

[MattyDucati]

Get ya camera man a better camera for them youtube vid's. We want to see them in HD :) Good work

[Rocket]

Heh. Yeah the old iPhone isnt the best.
Will do better next time.