Boosters new project

Just sold old faithfull:( had her for 7 yrs and done lots of stuff, 2 trips to the salt, drag raced , everyday road bike and long distance touring
Here at Casino
http://img.photobucket.com/albums/v3...afr0851ii0.jpg
First year at the salt in 04 ,198 mph
http://img.photobucket.com/albums/v3...tbackup021.jpg
This year at the salt , 218 mph
http://img.photobucket.com/albums/v3.../Boys08113.jpg
Final specs, 01 busa,gt30r, air to air intercooler,slightly beefed up motor and clutch

Replacing with this
http://img.photobucket.com/albums/v3...0/IMGP6567.jpg
08 busa
going to get a gt30r ,water/air intercooler, and needs lots of motor mods to keep it reliable , later busa's are not as good for turbo as the early ,
And yes it keeps the tupperware, if i was going to remove that i would have just brought a B-King , nearly did except for the price of this bike :D
Will keep adding to this as i build the turbo kit

Fantastic Greg,looking forward to seeing it progress..BTW a while ago i suggested that if you had the time could you rite a piece about the run at the salt from a builder/rider point of view, im facinated by the speed trials but only know from what ive seen/read.i would love to know what you need to do during the run up to full speed ,the afect of wind and other factors ,i know i should just have a go but not at the moment,anyway good on ya for what youve already achieved with much more to come..

Shame to see the old one go, but new projects are always fun. I'll have to come over and have a look.

Morry i have good intentions of writing that piece, figure if nothing else it may help others that have thought about coming out for a run, may actually take a whilt till i can sit down and put it together, have a few vids and pics to include (if i can figure out how to embed a vid .
Have to wait till after next weekend at least Clint, 08 is still in QLD , no time even to fly up and ride home so its a carrier job to get it here
may find it landing on your doorstep yet , will need an excuse to take the new one out and get familiar with it :)

Thats fantastic greg, thanks mate

I can ride it down for you mate ;);););)








And you just pay fuel,accomodation,return air fare,beer money etc :D

It's ok with me if you get it delivered here. I promise i won't ride it..............much.

I have a feeling courier may be cheaper than beer money Russ :D:D

Not ridable without sorting out the dodgy ign switch, these had a recall , routing of the switch wiring pulled on the wires , this one has an intermittant fault, , shouldn't take long to track it down , but not likely to go around the block without some pushing at the moment

Quote:

---

quote:not likely to go around the block without some pushing at the moment

---

sounds like half the bikes I already own

Quick update..
Don't try and get a VIV in Vic at the moment, the system sucks, been waiting for 5 weeks to get on the waiting list for an inspection,now on the list but no booking of a time or place yet, will be notified when there is a vacancy....

http://www.asfphotos.com/upload/1277147948.jpg


http://www.asfphotos.com/upload/1277160221.jpg


But while waiting i have been collecting some parts
Going with a water/air intercooled, gt30 turbo, engine management will all be done by reflashing the std ecu ,
for those that are interested you can download the reflash program for free here http://macmadigan.no-ip.com/ecueditor/

The plenum pictured is actually off my current 750 build , but the parts for assembly are for the busa,

currently waiting on the headers and wastegate mounts, brought them this time as i was getting in 2 other kits and getting a good deal for buying bulk .

Hey Greg the delay for VIVs is due to the hail damage. We have been told could be up to 3 month wait.

:)[8D];)

Yep the hail damage and a system that was never designed to cope with the numbers , hail was in March, talked to a viv centre last week, they had been quiet untill 2 weeks ago when Vic roads finally got things happening...other problem is if you have hail damage and you have a booking you can register your vehicle and then get it inspected within 6 months, but if accident damaged you have to wait till its inspected :(

Anyone have any ideas of rolling the plenum after installing the spigots and cooler, like to have the welds internal if possible , thought about making a custom roller with a long handle, like a small pipe bender but on a larger scale and anneiling the aluminium if necessary to make it bend easier, 3mm material

Quote:

---

quote:Originally posted by Booster

Yep the hail damage and a system that was never designed to cope with the numbers , hail was in March, talked to a viv centre last week, they had been quiet untill 2 weeks ago when Vic roads finally got things happening...other problem is if you have hail damage and you have a booking you can register your vehicle and then get it inspected within 6 months, but if accident damaged you have to wait till its inspected :(

Anyone have any ideas of rolling the plenum after installing the spigots and cooler, like to have the welds internal if possible , thought about making a custom roller with a long handle, like a small pipe bender but on a larger scale and anneiling the aluminium if necessary to make it bend easier, 3mm material

---

What sort of shape are you trying to do?

Fencing wire and twine, come on farmer Greg:D

Like tony asked, it would be easier if we knew what shape your after.

End result like the plenum with water intercooler attached above
or on its own
http://www.asfphotos.com/upload/1277242613.jpg


Realy like to weld the intercooler on first before folding as trying to get into the tight angle if assembling after folding is difficult with the thermal mass of the intercooler and the much thinner plate
and if the spigots or velocity stacks could be done on the inside too that would be the cream on top :D

WOOO HOOO ...Booked the VIV , 1 July , will try and book the roadworthy and rego the next day
Then the fun can begin :)

Well what a pain the whole viv etc is but its finally done
now back to playing
Powdercoated the new swingarm
http://www.asfphotos.com/upload/1278979106.jpg

Welded in the velocity stacks and intercooler core, now to see if i can fold the plenum from sheet form to the finished shape.
plan b is to cut it ,roll the top and weld it back on with the seams at least on the bottom

http://www.asfphotos.com/upload/1278925574.jpg


http://www.asfphotos.com/upload/1279013259.jpg


had Aussie desertcoolers make me the heat exchangers, very nice job

http://www.asfphotos.com/upload/1278957483.jpg

the nylon braided hose and fittings are due this week
and will be checking out the in tank pump and non pressure referenced reg later this evening, plan b here is to have a external 1:1 regulator if i can't get the internal regulator to the pressure i want, squashing regulators in the vise is not an exact science, practiced on one last week and went from 55 psi to 80- psi in ~.5mm crush but 43 psi to 55 psi took 1.2 mm :(
picture me with a bucket of fuel, a intank pump fully mounted in its fitting, in the bucket , a pressure gauge connected to the pump outlet, and 2 wires coming off a battery via a switch dissapearing into the fuel :D worked well , but i was not goint to be leaning over it at any time, those 2 wires were quite long...

http://i5.photobucket.com/albums/y19...athurst061.jpg
nice work Greg,heres a pic i took at Casino 08'of the ol'girl.

Thanks Ken
Nice pic :)

Still not sure i have done the right thing selling her, new one feels gutless at the moment .

testing the new intank pump showed it was not up to the task, in tank filter must choke it a fair bit even though it seems to flow through fine , could only flow 1000cc/min at 65 psi which is about 1000cc short of my needs,.... does 1600cc at 43 psi (roughly 300 hp)
if anyone wants a hi flow bosch in tank pump to fit in std suzuki position , call me .

Could you run two pumps in there back to back ? If theres room? I did that in an old carb celica tank to get them hidden in tank with then T'ed inside the tank .

Pump sits in a neat fitting well in the bottom of the tank, i'll just put an external pump on it, worked fine for the last 10 turbo's i have done was just looking for a std looking under the tank option, but i'm not about to compromise hp for neat ;)

could put an 040 bosch in the tank but with all the stuffing around mounting and plumbing its just simpler to do it external

haha you've seen betty , I care little for pritty lol

Normally i'm more for function over form too but i gotta admit seeing realy nice jobs done on such a variety of bikes here has inspired me to try a bit harder this time
heat exchanger is mounted
http://img.photobucket.com/albums/v3...0/08busa12.jpg
http://img.photobucket.com/albums/v3...0/08busa14.jpg
Had to bend it a bit more to fit in tighter , bit nervous when i put it in the press but it bent ok between a couple of blocks of pine 4x4 and a 4" pipe

Oh shit ... how long where you looking at the press with it ready to go before you give it a push?

Have you done the plenum yet... You need a piece of pipe to role it around ....

about 2 secs :D, if i stopped long enough to think about consequences i would miss out on too much fun [:p]

Keep getting work interfering with play, i want to do the plenum when i have time to make a proper roller, maybe on the weekend, lots of other stuff to do , i'm making 3 of everything 1 for me and 2 for mates .
Tomorrow i want to get the fuel system up and running including the wiring for the intercooler pump it will be on the original fuel pump wiring and also triggering a relay for the new fuel pump circuit

Yeah that work shit can be a real pain in the ass when the fun is really happening lol

Been getting a bit more done
Up pipe cut into the ram air tube,

http://www.asfphotos.com/upload/1280235304.jpg


Fuel pump , reg and general lay out
http://www.asfphotos.com/upload/1280268439.jpg


Fitting the cyls on the freshly coated pistons, 2mm decompression plate in gold
http://www.asfphotos.com/upload/1280245891.jpg


Titanium valves and light springs removed, they don't like heat much , replaced with std 99-07 valves and APE 65LB springs
http://www.asfphotos.com/upload/1280322098.jpg


Decompression plate lifting the head 2mm rolls the cams forward, so a spline tooth is cut from gear and the gear repositioned on the master spline on the crank to put the timing as std,
real handy that the gear has 18 teeth and 17 splines , works out that for each spline the gear is rotated its a ~.5deg advance or retard depending on direction, 5 teeth do nicely
http://www.asfphotos.com/upload/1280270184.jpg

any thing wrong with ur cell phone Booster? meaning the dates? [:p]

"2mm decompression plate in gold"

Did you win the lotto Greg?
Why gold?
What fuel fliter are you using.. 10µm .. 40µm?

Na Its just ballast Ivan haha, looking good greg.

Bloody camera, looses its memory when the battries are out, i'll get the right ones one day and be able to charge it "in camera"

Only coppercoat Ivan, Aluminium spacer
Not actually sure in the filter , enough to keep the big bits out of the pump , at least there the stainless screen type and not the sintered bronze, have a pet hate of them.

Hey Greg why have you opted for decompression plate, seems a helluva lot of fuck around with the timing chain thingamy!

Machine pistons, alternate?

Pistons are thin enough already,even aftermarket turbo pistons use a decomp plate as you can't get a good dish in the piston and proper quench or piston to head clearance between the piston pin and head without lifting the cyls and head up ..
The timing sprocket only takes a few min s to do and its easy to get out out anyway with the cyls off , pre 05 there was no master spline and you could just rotate the sprocket ...
Guys in the US fit adjustable sprockets and set the timing at ~105 deg but i figure the std timing at 102-105 is not too bad and if i can put it back to that i'm happy , my racebike gets more like 110 deg to move the torque curve higher and give it a few more rpm before it noses over but i would rather more bottom end torque esp as i will loose about 20hp with the decompression, (but put back 50 with more boost)

greg,

what injectors are you using mate. I have an 044,rising rate reg...big fuel rail blah..... base spacer... should we run sloted gears?

cheers

Pete

Pete its a whole new ball game with the 08+
2 x 280cc injectors/cyl std, with the ecu editor stuff now i can program the std ecu to do boost based mapping,vary the ign dwell for more spark energy,onboard boost control, turn off fault codes from disused sensors,and heaps more
www,ecueditor.com is where you can download the programme and see its capabilitys and, www.boostbysmith.com has the hardware

I have never compared the hp between retiming the cams or not, heard one report of something like 7 hp it advances the cams ~3.5 deg which will put your power earlier in the rev range and at worst limit the rpm your bike can pull, it may not be worth doing if your happy with how its running
i don't bother when doing a 1mm spacer , but did notice on the 750 with 2mm spacer and not retimed that it couldn't pull passed 12000

Bit more done over the last few days
Plenum is rolled , actually happened quite easily once i started putting together the bits to roll it

http://www.asfphotos.com/upload/1280888161.jpg


ends in, bov mounted, still to do the tiedown mounts
http://www.asfphotos.com/upload/1280848559.jpg

How neat are these RCC headers, one piece cast flange with the pipes fitted in and welded, and a 2 yr warranty

http://www.asfphotos.com/upload/1280833528.jpg


While i was doing the plenum i gave the compressor housings and up pipes to the local powdercoater, looks like a natural part of the bike now


http://www.asfphotos.com/upload/1280843319.jpg


Started the bike for the first time last nite, fired first turn and ran sweet, just have to do the exhaust from the wastegate out and i can have somewhere to hang the o2 sensor and dyno it [:p]

nice work Greg,was interested in your cam timing specs.its always good to see what works in different applications and engine configerations

By no means am I an expert but changing lobe centres on cam timing in my experience simply moves the power around doesn't necessarily give you any more e.g. retard timing more cylinder pressure more torque advance it less cylinder pressure but better top end, of course things change when you are charging the cylinder but thats my experience.

Standard I have found is generally the best if you can get it to work.