PROJECT TURBO BUSA IS NOW A GO

bikes just got an mot
and apart from oil cooler needs moving a tad alls cool
mechanic took it out for a spin and it looks like its got a fueling problem
and bogging down:
i took it for a spin and yep not quite there yet :mad:so its got to on the dyno
and get sorted so waiting on some contacts that wont rip me off any ideas
based in middx:rolleyes:

heres some daylight shots

http://i15.photobucket.com/albums/a389/spart666/4-1.jpg

http://i15.photobucket.com/albums/a389/spart666/3-2.jpg

http://i15.photobucket.com/albums/a389/spart666/2-1.jpg

http://i15.photobucket.com/albums/a389/spart666/1-1.jpg

Sweet great looking bike

Fucking hell that thing is awesome !

Looks fucking tough mate

That's bloody awesome... one of my fav bikes on here now.

Awesome mate....well done 8)

Looks good mate well done.

I would have a play with some adjustable dog bones though. Looks a little to steep on the swingarm angle given it is a longer than standard swinger makes it look steeper too

an update

so far its been a bloddy nightmare if it can go wrong it has starting with 2 weeks for a lead for the ecu better than spending 160 on buying one i supose
one fuel hose was fractured, sorted. bike was running lean on dyno hugh misfire no power after 180bhp. inspect and balance t/bs
repaired pick up wire and replumbed turbo smart and rewired
still wouldent respond to mapping
stripped out plennnum and throttle boddies checked pump and filter found the filter was fucked like proper fucked
throttle bodies had bent butterfly repaired and replaced filter. re balanced
back on the dyno was better but now massively rich remapped but kept drifting in and out
so contacted sbd for info and took the bike to sbd for fault finding looks like the software was 4 years old got the ecu software upgradded and found the compensations inputed wrong so adjusted
t/bs still playing up and coolent sensor not steady
some more rewiring and change coolent sensor
back on dyno starts to map and run ok keeps loosing boost
furthur inspection in the workshop found that the headers were cracked
all the way around (main section were it goes 4 into one)
so good news all the probs found so far headers comming off monday when i get back from work then probably off to stainless dave to weld them up properly then back to ken to remap
bike rides lovely and he sorted out the throttle issue just needs to come onto boost recon kens used up a lot of favours on my behalf
will post up the fucked headers once i got them off
so much for rebuild and ride:rolleyes:

phew, that's mega!

don't you park next to me at the show mate, I want people to look at mine first before dribbling over yours lol remind me not to park next to Steve or that CBX either lmao

note to self
park next to noz as she wants people dribbling over my bike
and you will be doing what to make that happen you harlot:D

Don't you just love custom bikes:D

Good to see she's giving you a fun time[}:)]

Holy fuck how did I miss this that looks shit hot

what a couple of weeks
a big thank you to dan for sorting out the studs in the turbo
dave for welding and turning the headers around in 24 hours
esm for getting the header flange milled flat in one day
and kjb busa for the oil cooler and not forgetting exile
for giving us a hand to put the turbo back on
all sorted and on the road
all thats left to do is get it back to kens for some sorting reving a little high and to sort the boost out
got its studio shoot done today thanks will rob dave a good day out

http://i15.photobucket.com/albums/a3...6/P1050341.jpg

http://i15.photobucket.com/albums/a3...6/P1050340.jpg

http://i15.photobucket.com/albums/a3...6/P1050339.jpg

an intresting way of getting the bike to the studio:)

http://i15.photobucket.com/albums/a3...6/P1050612.jpg

due to the current state of the economy even sf mag has had to cut back so wilma jobbins to the rescue we left before the mankini came out


http://i15.photobucket.com/albums/a3...6/P1050639.jpg

http://i15.photobucket.com/albums/a3...6/P1050654.jpg

http://i15.photobucket.com/albums/a3...6/P1050657.jpg

http://i15.photobucket.com/albums/a3...6/P1050676.jpg

got ya monkey boy:)

http://i15.photobucket.com/albums/a3...6/P1050677.jpg

http://i15.photobucket.com/albums/a3...6/P1050679.jpg

http://i15.photobucket.com/albums/a3...6/P1050661.jpg

http://i15.photobucket.com/albums/a3...6/P1050642.jpg

http://i15.photobucket.com/albums/a3...6/P1050629.jpg

http://i15.photobucket.com/albums/a3...6/P1050627.jpg

and thanks guys for making elise welcome

http://i15.photobucket.com/albums/a3...6/P1050673.jpg

will update the studio shots when i get them with the usual flesh shots ect

Thats unreal Spart! Congrats mate!

so are they her snail trails ??

^^^^^fuck...spat beer on the commputer screen..that is one mean mutha spart well done

Mate that looks unreal, you done a top job mate congrats!

Bike's looking tops mate. Job well done

Fuck yeah that's awesome and good to see will hasn't lost his sense of humor

Awesome job mate very well done

some updates
decided to get rid of the cooler knew it was close to the wheel
but found that its definatly rubbing under braking so dont really wanna find out
what happens when i have to slam them on other niggly bit is that the cooler touches the turbo which vibrates like fuck so bite the bullet off to think automotive who did me a good deal on a new cooler lines and fittings
off to see bill on wed to get the revs sorted and some dyno time so i can get out and enjoy whatever summer we have left
sfc sorting me lights out and motogadgets speedo back to germany to get sorted looks like in blew a diode somehow:rolleyes:

http://i15.photobucket.com/albums/a389/spart666/2-1.jpg

just so you get an idea how close the cooler was to that wheel

http://i15.photobucket.com/albums/a3...6/P1050718.jpg

loads of space now

http://i15.photobucket.com/albums/a3...6/P1050714.jpg

how small is that been told they are more efficient than a standard cooler anyone explain it to me properly? in baby english

http://i15.photobucket.com/albums/a3...6/P1050715.jpg

http://i15.photobucket.com/albums/a3...6/P1050720.jpg

http://i15.photobucket.com/albums/a3...6/P1050721.jpg

http://i15.photobucket.com/albums/a3...6/P1050738.jpg

http://i15.photobucket.com/albums/a3...6/P1050741.jpg

last job was to remount the cooler bottle on the other side reroute tubing
simples

http://i15.photobucket.com/albums/a3...6/P1050729.jpg

so it's a water cooled oil cooler? thats fucking cool...

supose id better update
got the bike down to bills (dynomutt)sorted out the revs but still hunting but now usable had a lug break off on the rad got that sorted and rewelded bill also sorted out a leak on the sump and decided to sort out the clocks
carl is still sorting out a carbon insert for the ram air and healight cover in carbon think were gonna go with the busa jap logo cut out of it
carl did finish it but went at it with a hammer when his kid said it looked like a jammy dodger!!!!!
bike went back onto bill dyno good news tick over sorted goes well up to 4k bad news then badly goes rich was putting out 120bhp at 3.5k revs thats pretty much tickover :)

http://i15.photobucket.com/albums/a3...h_IMG_0642.jpg

so needs remapping decided to buy the leads needed to connect ecu to laptop got the software the ecu already been flashed with the latest software and spoke to jack at holeshot whos sending me the original mapping (really helpfull bloke) when it was pushing 287bhp so a good base to work from
thats it for now been sying that for ages cross fingers next two weeks back to sunny cornwall for bill to sort and get this beast running correctly

http://i15.photobucket.com/albums/a3...6/IMG_0671.jpg

http://i15.photobucket.com/albums/a3...6/IMG_0649.jpg

Absolute work of art mate! Hope u get it runnin right without too much hassle.

carls been busy got him to make me up a carbon
lightcover heres the mould cant wait to see how it comes out
playing with one or two or possibly 3 ideas after our last chat on the phone
cheers mate

http://i15.photobucket.com/albums/a3...087448x600.jpg

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some help guys
loads of niggly probs all now sorted
was up at bills for a couple of days utilising his dyno
got the leads for the ecu, software, holeshots mapping ect
try to keep this short
mapping is pretty spot on tick over is now spot on not hunting for fuel
running rich at approx 8k revs
the problem is not boosting
using an eboost 2 which is set to 8psi but when on the dyno only getting about 3.5 psi
wastgate is working blow off valve working no cracks in plen chamber headers not cracked all plumbing checked and correct turbos running
mappings correct
any ideas ?
have been told what it possibly could be but before i post it wanna see what you guys think

heres the spec
fully stripped and rebuilt new mains and big ends
cylinder head had the valve seats re-cut and lapped and some minor porting
bearings and seals heavy duty headstuds
heavy duty clutch springs
forged je pistons, barrel spacer
modded clutch basket billet clutch slave support bracket
garrett gt25 turbo charger
tial 38mm wastegate
small dump pipe k&n cone filter
alloy plenham chamber
fuel m,ment MBE 9A4 ECU
MODIFIED HARNESS TO SUIT ECU
3 BAR MAP SENSOR
h/d FUEL PUMP
HEAVY DUTY FUEL INJECTORS
TOP HATS AND CLIPS
EBOOST 2 BOOST CONTROLLER
NEW REGULATOR/RECTIFIER

ohhhhh yea and a vid of bill giving it some

http://i15.photobucket.com/albums/a3...h_IMG_0686.jpg

if theres no leak then either the turbine shaft or the wheels r fucked up there r no miracles only lack of data geezer

Quote:

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quote:Originally posted by Surt

if theres no leak then either the turbine shaft or the wheels r fucked up there r no miracles only lack of data geezer

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that all looks ok its making boost but not enough
looks like it may be the 3 bar map sensor thats creating the issue this stuff is over my head still learning:D

mate carl just made these up for me
mto3 carbon headlight covers
and the carbon inserts for the frame
wot you recon
i think the first two look spot on

http://i15.photobucket.com/albums/a3...6600_x_448.jpg

http://i15.photobucket.com/albums/a3...7600_x_448.jpg

http://i15.photobucket.com/albums/a3...5600_x_448.jpg

They look great mate ...which one is for sale ..I'm keen

Quote:

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quote:Originally posted by BANDITROD

They look great mate ...which one is for sale ..I'm keen

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give it a couple of weeks and il give you a contact
for them

Disconnect the boost controller and see what happens. If you get wastegate spring pressure then the boost controller is at fault

Quote:

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quote:Originally posted by spart666

Quote:

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quote:Originally posted by Surt

if theres no leak then either the turbine shaft or the wheels r fucked up there r no miracles only lack of data geezer

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that all looks ok its making boost but not enough
looks like it may be the 3 bar map sensor thats creating the issue this stuff is over my head still learning:D

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if u haint seen the blades flyin out of the hair dryer then yup the eboost is fuckin ur brain just remove hoses from wg to work in manual mode and see wat happens... to obvious answer im afraid but good luck anyway mate

progress at last
went down to dyno mutts this morning and he fitted the new 3 bar MAP sensor, and it started boosting, not much though, so further investigation discovered the throttle bodies on cylinders 3&4 were lifting under boost along with the plenum. it looked more like ejecting Once this was sorted first run saw 175bhp @6 psi then another @ 216bhp @7psi and then 242bhp at 8psi. Fueling is still a little rich at WOT and lean off boost, but that will be sorted once the thing is boosting to the required pressure, bill recons there is still a boost leak somewhere which will be tracked down over the next few days, then he can start to adjust the fueling via the MBE ECU, using the Easimap6 software
and find those missing 40+ ponies

heres our starting point

http://i15.photobucket.com/albums/a3...42bhpgraph.jpg

Hi guys
all weve managed to do is find problems but we are getting there
last post we had the bike boosting pushing 242bhp @ 8 psi bill (Mustapha dump to you lot)
couldent get the bike to boost higher than 8 psi so reckoned since the wiring loom has been hacked about so many times could be creating an issue with the eboost
his answer redo it he got rid of the over complicated eboost i got hold of some new guages
and sorted them to fit bill rewired them and cut another hole in my tank:)

http://i15.photobucket.com/albums/a3...666/dials5.jpg

http://i15.photobucket.com/albums/a3...666/dials2.jpg

http://i15.photobucket.com/albums/a3...666/dials3.jpg

http://i15.photobucket.com/albums/a3...666/dials4.jpg

result was 288bhp 160lb/ft at 12 psi.
bill says "This was the first test of the new boost control system.
The new spec is
1st stage 8psi on the wastegate spring alone 240bhp, push the button and 2nd stage is engaged which sends boost pressure to the top of the diaphram, when the boost pressure reaches the desired level the adjustable boost pressure switch in the plenum

http://i15.photobucket.com/albums/a3...666/plen22.jpg

http://i15.photobucket.com/albums/a3...666/plen21.jpg

switches the 3 way air solenoid and the wastegate opens, the new system allows boost pressure from 8 to 18 psi, simply by winding in the adjuster on the pressure switch in the pleneum. The system is designed that in the event of power failure or component failure the boost will default to the low setting

http://i15.photobucket.com/albums/a3...66/dials71.jpg

A latching push button is mounted between the new digital boost gauge and matching digital temp gauge supplied by Visual Performance, when the 2nd stage is active a red warining LED in between the gauges illuminates, this LED goes out when the wastegate opens.

seperate subloom was built for the new boost control to avoid having to do anything to the existing wiring system. The valve clearances on several of the intake valves were far too tight and the intakes were holding open slightly when the motor got hot.

The graph attatched was the first test of the new system and managed 288bhp and 160lb/ft of torque at 12psi.

http://i15.photobucket.com/albums/a3...rol1sttest.jpg

on high boost, bill was going to turn the boost up and get it to 300bhp but the fucking wiring gremlins have raised there fucking heads again bill managed a couple of runs but the ignition keeps breaking down one minute its fine next not
result you touch the wiring loom you dont know if the bike will start or not or how its going to behave and to give bill his due his worry is it fails me whilst im overtaking or mid corner ect ect
the other major point is we want realiability so got to bite the bullet
pretty sure bill will add his two pence worth at some stage

so blasted off an email to jack at holeshot with the issues and the result
a full wiring harness for mbe ecu
Injector Sub loom
Map sensor input loom
and bill is going to build a seperate loom for the lights ect
hes already built a subloom for the boost control part of system
so when we get this sorted bill can finally map it in and fine tune it

just had a look at the last two sf mags ive missed looks like busabastard is doing the rounds:)

http://i15.photobucket.com/albums/a3...6/scan0002.jpg

http://i15.photobucket.com/albums/a3...6/scan0005.jpg

http://i15.photobucket.com/albums/a3...6/scan0003.jpg

Yea, saw that in the Special edition. Yours will be in the next (march) edition apparently.

Wow that's some serious ponies for a bike, your knuckles are going to drag on the ground after just a few rides.;)

Well so far I've hit 292bhp with the new boost control system I've built for the bike, however the biggest problem is the wiring loom, which is pretty fucked!! It has been hacked about left, right, and centre, and is causing the bike to die intermittantly, so a new MBE Busa loom is on its way from Jack at Holeshot, once this arrives I'll fit it which will take care of the engine management side of things, I will then build a custom loom to run the rest of the bike, so effectitvely it will have two sublooms, one for the motor management and one for the ancillliaries, it will also have a small seperate harness running the new boost control system. This means that the wiring will be much easier to work on should it need other systems adding in at a later date, and it will stop the problems I'm having with the bike cutting out intermittantly.
Once this is done the bike will then have the mapping tweaked, the copy of the original map that Jack sent me is pretty good, and just needs a little adjustment.
When finished the adjustable boost control will allow boost levels from 8psi to 18psi. In low mode the boost is controlled by the spring in the wastegate alone, when the second mode is activated by the switch in between the boost gauge and temp gauge, boost pressure is applied above the wastegate diaphram, when boost pressure reaches the chosen level the adjustable pressure switch in the plenum switches off the solenoid controlling the boost pressure above the diaphram and the wastegate opens. The red LED illuminates when in high mode, and goes out when the wastegate opens. The whole system is designed so that in the vent of power failure or component failure the boost level will default to the lower setting. The initial test of the system achieved 283bhp and then 292bhp before the wiring issues raised their ugly heads again, so watch this space, next time I post we should be seeing the 300bhp target.

nice work mate. you should be real happy

Awesome work!
Read the article today in Streetfighters Mag.
Never wash that seat!!!!!!