Topic: New bike project.....Yes this one is going to be turbocharged, It rides! (Read 67504 times)

CSaddict · « **Reply #30 on:** June 07, 2009, 07:59:14 AM »

Stickied. Solid work Sky.

96turboracer · « **Reply #31 on:** June 11, 2009, 02:19:53 AM »

Thanks man, I hope to justify the sticky. hard to keep things updated regularly when life is crazy, but you all know that anyway. I'll do my best.

Got a fair amount of work done on the intake manifold recently:

here you can see the plenum and the throttle body feeding it, and here's a few shots that show the positioning:

tight fit, but it'll clear

In this shot you can see the holes I've cut for the runners, and also you can see my finished intake flanges:

I don't have the mandrel 90's I need to finish up the runners yet, or the alumnium injector bosses, but I should have those ordered soon. I also cut out the caps for the sides of the plenum, but I'm not going to weld those in place until everything else is welded up.

Also, I'm going to build a short bracket from the Throttle body to the upper motor mount to help support the manifold.

I'm having a blast welding this aluminum, it's really interesting material to weld, For my first major project I feel like it's going pretty good:

Also, on my previous project I cut up a handlebar I had lying around because I needed to make some spacers out of it for my calipers. All the time I was thinking I'm going to regret this because I'm going to need this eventually. Yep, sure did

So I got a length of 7/8" aluminum round stock and made sure everything was super straight and welded it on:

Anyone need an ultra long clip-on?

Now I just need to smooth the weld, cut it to factory length and tap the end for a bar end if I so choose.

Thanks for lookings guys, hope to keep updating fairly regularly but you all know how life keeps getting in the way of what we want to be doing!

Sky

dvst8r · « **Reply #32 on:** June 11, 2009, 10:08:15 AM »

Soild progress, Aluminum looks good for a first time.

96turboracer · « **Reply #33 on:** June 11, 2009, 08:17:57 PM »

Yeah buddy, got my front end in today, 2007 GSXR 600 forks and lower triple.

Looks like my assumptions are correct, the fork size is the same as ZX6r forks, so I can use my Kawi clip-ons, and also I'm going to use a Kawi upper triple.

Some pics, the bike visually is starting to come together, also I get my front wheel tomorrow, so expect to see some pics with that in place tomorrow sometime.

thanks
Sky

dvst8r · « **Reply #34 on:** June 11, 2009, 09:35:05 PM »

To show my complete lack of vision, I can just sorta imagine what it is going to look like as a finished product now.

Minor Threat · « **Reply #35 on:** June 11, 2009, 11:18:23 PM »

it's going to look like all the bikes i like the style of, plus it has a turbo.

onlyflash944 · « **Reply #36 on:** June 12, 2009, 12:22:15 AM »

i've got a good 14b if you change your mind again

nice fucking work on the aluminum. i think it looks pretty damn good, and way better than I can do. i'm too scared to even try shit like that with my syncrowave

shadow · « **Reply #37 on:** June 12, 2009, 12:54:18 AM »

is it me, the pics, or does the bike look really short?

looks badass either way, keep up the great work!

96turboracer · « **Reply #38 on:** June 12, 2009, 01:24:21 AM »

Quote from: shadow on June 12, 2009, 12:54:18 AM

is it me, the pics, or does the bike look really short?

looks badass either way, keep up the great work!

depends on what you mean by short, if you mean the wheelbase, it's actually and inch or two longer than all the current sportbikes have.

If you mean top to bottom, it's because I have the rear wheel in place without the front wheel, so in the pictures the swingarm is in the same position it would be in if the rear shock was fully compressed. Once I have the front wheel tomorrow I can mock it into place and start setting up the real ride height. seat height should actually be a few inches taller than most bikes.

crxvtec91 · « **Reply #39 on:** June 12, 2009, 04:45:39 PM »

Solid work, keep it up!

96turboracer · « **Reply #40 on:** June 12, 2009, 07:05:29 PM »

Got my front wheel on today! Mocked up anyway....

I'm really really liking how this bike looks right now. Should be awesome when finished:

thanks
Sky

bigdaddyvtec · « **Reply #41 on:** June 12, 2009, 07:18:13 PM »

:yes:

88dx · « **Reply #42 on:** June 12, 2009, 09:21:51 PM »

The Clip-on's seem like their going to be really low, but its hard to tell untill u get the rear set's on. Badass project :yes:

96turboracer · « **Reply #43 on:** June 13, 2009, 04:10:33 PM »

Quote from: 88dx on June 12, 2009, 09:21:51 PM

The Clip-on's seem like their going to be really low, but its hard to tell untill u get the rear set's on. Badass project :yes:

Yep, they are really low, I like a really aggresive look. This bike should be really fun for riding hard, but will probably be a bit of a torture rack for everyday riding. That's ok though, it's kinda my style ;D

96turboracer · « **Reply #44 on:** June 23, 2009, 03:08:28 AM »

Sorry for the delay, I was off on a trip for a few days.

Meanwhile today I did some more work on the intake manifold. It seems to be shaping up nicely so far, the injector bungs are in the mail and should be here on Thursday, but I'm clean out of argon gas, and don't really have the money for more right now, so updates might be a bit slim for the immediate future

Anyway, here's some pictures:

As you can see the runners are fully welded to the flanges, and are not even tacked to the plenum yet. A bit more work needs to be done to the tops of the runners to make them fit as well as possible.

A quick note about the runners, I was originally going to order some mandrel bent 90 degree elbows, but the thickest I could find them in was 16ga which is a waste of time trying to weld that to 1/2" aluminum. So I went to my local supply place and picked up a length of tubing which had the proper diameter I wanted. The catch? It's sch45 tubing, think that's thick enough

So quite a bit thicker than I needed, but hey, stronger is better right?

Anyway, hopefully things will turn around for me fairly quickly here and you'll get some better updates.

Later
Sky

j.h.christ · « **Reply #45 on:** June 23, 2009, 07:02:35 AM »

this thread is awesome. i have a almost new k03 and audi side mount IC that i would love to trade you for that k04, if you decide you want a k03.

CSaddict · « **Reply #46 on:** June 23, 2009, 08:29:21 AM »

I think that is a good trade. The K03 would be better suited for the small displacement I would think.

Looks great Sky. Keep it up!

dvst8r · « **Reply #47 on:** June 23, 2009, 09:08:51 AM »

+2 on the K03 over the K04

SloS13 · « **Reply #48 on:** June 23, 2009, 10:27:18 AM »

awwwww shit badass thread.

dvst8r · « **Reply #49 on:** June 23, 2009, 10:34:53 AM »

One quick question are your intake runners that vertical and that close to the head for a lack of space? It looks in the picture to have an awfully tight radius going into the head.

Yeah welding thick aluminum to thin aluminum (or for that matter anything thick to anything thing) takes a fair bit of practice, aluminum is especially bad as it is a good heat sink and the thick aluminum takes so much heat. Preheating the thick piece can make it go a lot better, but mostly like anything it is just practice.

96turboracer · « **Reply #50 on:** June 23, 2009, 01:09:18 PM »

Quote from: j.h.christ on June 23, 2009, 07:02:35 AM

i have a almost new k03 and audi side mount IC that i would love to trade you for that k04, if you decide you want a k03.

That might be a possibility. do you think you could post up a couple pictures of the turbo and intercooler, along with the dimensions of the intercooler?

I like the turbo I have, the compressor map seems good, but if I have a chance to get an intercooler out of it, I should at least take a look.

dvst8r- yea the runners do have a fairly harsh turn into the head, but it shouldn't really be a problem when you're forcing 12lbs of air through them. Also, I did mainly make them that way for space. The turbo has to fit behind them.

Also, I wish I did have a way to preheat the aluminum that would be really nice.

dvst8r · « **Reply #51 on:** June 23, 2009, 01:32:45 PM »

Quote from: 96turboracer on June 23, 2009, 01:09:18 PM

Quote from: j.h.christ on June 23, 2009, 07:02:35 AM
i have a almost new k03 and audi side mount IC that i would love to trade you for that k04, if you decide you want a k03.

That might be a possibility. do you think you could post up a couple pictures of the turbo and intercooler, along with the dimensions of the intercooler?

I like the turbo I have, the compressor map seems good, but if I have a chance to get an intercooler out of it, I should at least take a look.

dvst8r- yea the runners do have a fairly harsh turn into the head, but it shouldn't really be a problem when you're forcing 12lbs of air through them. Also, I did mainly make them that way for space. The turbo has to fit behind them.

Also, I wish I did have a way to preheat the aluminum that would be really nice.

K03 is very close in map to the K04 with the K04 being able to flow slightly more on the top end, and the K03 providing quicker spool up.

I kinda was guessing that packaging was the big concern there as a bike you have really limited space, and everything is a compromise.

Electric frying pan works wonders.

dvst8r · « **Reply #52 on:** June 23, 2009, 01:45:34 PM »

Here are the K03 and K04 maps, from a quick google search:
K03

K04

96turboracer · « **Reply #53 on:** June 23, 2009, 02:58:11 PM »

thanks for the maps. The k04 map i was looking at has a more lenient surge limit. It's kind of frustrating because there's so many different versions!

j.h.christ · « **Reply #54 on:** June 23, 2009, 03:14:28 PM »

Quote from: dvst8r on June 23, 2009, 01:32:45 PM

Quote from: 96turboracer on June 23, 2009, 01:09:18 PM

i have a almost new k03 and audi side mount IC that i would love to trade you for that k04, if you decide you want a k03.

That might be a possibility. do you think you could post up a couple pictures of the turbo and intercooler, along with the dimensions of the intercooler?

I like the turbo I have, the compressor map seems good, but if I have a chance to get an intercooler out of it, I should at least take a look.

dvst8r- yea the runners do have a fairly harsh turn into the head, but it shouldn't really be a problem when you're forcing 12lbs of air through them. Also, I did mainly make them that way for space. The turbo has to fit behind them.

Also, I wish I did have a way to preheat the aluminum that would be really nice.

i will have pics up for ya tonight. it's a standard 1.8t intercooler, pretty damn small, bur if you're constricted by space, they are wonderful. is the k04 out of the 225 hp TT?

dvst8r · « **Reply #55 on:** June 23, 2009, 03:18:36 PM »

From what I understand those are the standard VW / Audi K03 and K04 maps, I found them on the vwvortex.

As you can see the K03 is still good for 20lbs/min @ ~26psi, which is about 200hp worth of air, or more then double your stated goal. As well the surge line is nearly vertical, it is almost impossible to surge that turbo. As well you should be about right in the middle of the sweet spot.

The K04 is good for approx 300hp, and would work well for your application, albeit you will be riding a little to the left of the sweet spot.

dvst8r · « **Reply #56 on:** June 23, 2009, 03:27:09 PM »

It has been awhile since I have held a stock 1.8t smic in my hands, but I think they are about 8"x8"x2" (my guess)

We will wait for Christ to post up the actual specs and pics.

spiceisler · « **Reply #57 on:** June 25, 2009, 03:31:45 PM »

Badass project man!! Subscribed.

AfroIntegra · « **Reply #58 on:** July 07, 2009, 04:53:04 PM »

Awesome work man!

d-rail · « **Reply #59 on:** July 08, 2009, 04:23:29 AM »

Did you die? NO UPDATES!!!!!!!!

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Author Topic: New bike project.....Yes this one is going to be turbocharged, It rides! (Read 67504 times)