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[96turboracer]

My kid never goes to bed, she's got my sleeping habits 

[jarebear667]

nice work! i followed your old build on Ohmt.  i like this one more!

[96turboracer]

Whew! About time for an update wouldn't you say?

I worked more on the tail section. It wasn't quite straight before, so I had to cut some of it apart to straighten it. I'm much happier now. I also made some tabs to mount the tail-light and the seat. The seat is going to take some more work to finalize the mounting, but at least it stays in place now.

Then, to get an idea of what the tail is going to look like skinned up, I covered it with painters' tape



Definitely achieved my goal of replicating the KTM RC8 tail!









I also worked some more on the turbo manifold. Because of the way it mounts, there's no way to make the manifold in one piece, so I made a sleeve. This sleeve will have tabs welded at the ends where it joins on the top and bottom with a spring between the tabs, just for extra insurance.

I also made the flanges where the tubes insert into the head:

Here you can see both the sleeve and the flanges:



Pretty happy with my stainless welding right now



Now that these items are done, all I have to do is get the turbo in its final mounting position, then I can tack the remainder of the manifold together, hooray!

Also, I finally got some of my pieces cut at a friends who has a CNC plasma cutter.

I designed these parts in autocad and he cut them out. The plasma cutter is only precise to a point, these have definitely been cleaned up after cutting, but however it still can make some really cool parts. It's quite the cool feeling to design something on a computer then watch it being cut out. It's fabrication in another capacity.



The part on the bottom right is the baseplate for the sprocket adapter I'm building, this will be welded to the studs that screw into the factory holes. Obviously this will make the adapter non-removable. This is not optimal, but necessary for space reasons.

The part on the bottom left is the outer adapter ring that will be welded to the base ring. It will have studs welded in place for the actual sprocket.

All this work is necessary to run the extremely small 30t sprocket on the factory CBR F3 cush drive.

Also, because the sprocket adapter will take up space, the cush drive needed to be milled down, here's a shot of it after I milled it down:





The final part on the top is the turbine exhaust outlet flange.



Again, as soon as the turbo is mounted I'll be able to finish out the exhaust.

Stay tuned, lots of good stuff to come.
thanks
Sky

[dvst8r]

Looking good, always lots of innovation in these posts I love it.

[hatrack48]

great update Sky, I like the way you incoperated those tail lights

[Joseph Davis]

 

[96turboracer]

got to finish tacking together the turbo manifold today! Here's some pics:



On this side you can see the sleeve I made so the manifold can be removed in two pieces:



And I got the turbo mounting tabs in place, so the weight of the turbo is not hanging on the manifold. The manifold will have a couple extra mounting points as well.

With the turbo mounted I was able to work on the exhaust as well, 2.5" baby With a turbo, the less exhuast the better, and that's the mantra I'm following:







The end will be slash cut a couple inches after it exits the subrame, just haven't cut it off yet.

I didn't like the swingarm pivot I made, so I decided to use a stock XS650 swingarm pivot, here's the piece:



It'll be all chopped up here shortly and I can start building the new swinger.

Here's a few shots of the bike mocked up again:







I think it looks cool with all the tubing running everywhere and there'll be even more after I mount the intercooler and make the piping for that.

Also, I got a new tool the other day, check it out:



Little 3/8" drive impact. Supposed to be able to go all the way up to 85ft/lbs which is way more than I ever use. I bolt and unbolt a lot of stuff on this bike, and doing it with wrenches is soooo slow, decided to speed things up a bit! working awesome so far.

Thanks again for checking out my build, hope to have a new update soon.
Sky

[onlyflash944]

love the rear tire warmer.   you just going to rock the whitey manifold or make a jig and get some mandrel bends?

[dvst8r]

I have no vision for how things will look when they are done, but its finally getting to that point were I can see it. Good work as always.

[96turboracer]

love the rear tire warmer.   you just going to rock the whitey manifold or make a jig and get some mandrel bends?

Nah, that manifold is done as is. After I weld it all up I'm going to polish it up a bit, hopefully then it'll turn a nice shade of gold or something. Also, generally the bends I'm using are too tight for mandrels.

[onlyflash944]

word.  i guess sch. 5 pipe is a little hard to come by for cheap


still looks awesome.

[97Econobox]

wow that is sexy.

[glustic]

I can't get over how much fabrication is involved. This is going to be tits.

[bigdaddyvtec]

I FUCKIN LOVE IT,


Just a lil opinion/input... The rear section would look alot better with the top of it lower... Looks REALLLY tall in the rear.

[gsx750r93]

I FUCKIN LOVE IT,


Just a lil opinion/input... The rear section would look alot better with the top of it lower... Looks REALLLY tall in the rear.

Keep in mind there is no tire on it so thats gonna make it a little closer to the rear tail. It also appears to be sitting on the frame so I would believe it will drop a little when there is tension on the swing arm.

What happened to the old tail. I liked it a lot.

[bigdaddyvtec]

I kept it in mind. Its tall... REAL tall....

[turbob16hatch]

I kept it in mind. Its tall... REAL tall....

yup

[robus]

What happened to the old tail. I liked it a lot.

x 2

[brine04]

Is Skye still alive? We want ripper vids!

[CSaddict]

Gonna drop the stickie for now. Sky must be busy.

[96turboracer]

Gonna drop the stickie for now. Sky must be busy.

Sorry guys, haven't been able to get at this much lately, too much going on. And it doesn't look like I'll be able to get back on it soon either.

Good news though, I just got a job at a fabrication shop back in Bend Oregon. So I'll be moving back over there next thursday!  Very excited about that, unfortunately we won't have our own place for about a month or so, so it'll be at least that long until I can get the project moved over there and start working on it again.

Never fear though, this thing will get done! Stupid life just keeps getting in the way....

I'll definitely let you know when I get crackin' on it again.

[dvst8r]

Glad to hear you got another job Sky.

[Joseph Davis]

Employment - a RHMT tradition since 2009.   

[97Econobox]

Employment - a RHMT tradition since 2009.   

.......ok so im not going to go there since you got all butt hurt and stuff but i know someone will...........


lol.


Glad you found a spot Sky, cant wait to see how this ends up once you find time however busy is good.

[HiProfile]

I couldn't put my finger on it, but now I see it. You just need some wings now:







 

[96turboracer]

Haha  ;D

That's awesome, I wish it were that easy to make!

Thanks for the support guys, I leave tomorrow and start Monday. Definitely stressful....

[jarebear667]

ding dong.

[96turboracer]

No, I'm not dead

Go ahead and skip this paragraph if all you want to see is the bike stuff:
Man, what a series of events! I got a job back in Central Oregon, moved my family over there, and it fell apart almost immediately. I was completely floored and definitely depressed about it all. I stayed in Bend for another month trying to find some suitable work over there but it just wasn't happening.
So now I'm back over here on the coast again. Probably for awhile now. Anyway the good news is that the bike project was here all along, and now I'm able to work on it again. Yay!

Bike Content.....

So now that I'm back on the bike figured I'd update you guys on what I'm working on now. Still haven't finished the swingarm, although I am further along on it. I'm hoping to be done with that by the end of this weekend.

Also, i'm going to get started on skinning up the subframe with sheetmetal, and to that end I got a couple new tools:

Shears:


and a bead roller:


These are both harbor freight items, but the bead roller has been shown to be very productive if you beef up the frame a bit. The shears should work fine for the thin sheetmetal work I plan on doing.

Also, April 1st was my five year anniversary, here is my present!


What could it be you ask? Why only the coolest thing in the world! Megasquirt engine management. Full stand alone, This is going to be amazing!

and what's this with it?


Why that's electronic boost control! :banana

If you can't tell, I'm beyond thrilled to get this. It was definitely one of the more expensive things I needed for this bike, so that's nice to get it out of the way. Also, custom engine management is my thing, I'm geeky like that. I'll be playing with this thing for probably over a year after I get it running trying to tune it just perfectly.

Now for some actual work:

I was doing some research on wide band sensors, and found out that my original placement of the sensor in the turbo manifold would be a very bad idea. Apparently wideband sensors are not like narrowband sensors in that they do not like excessive heat. The documentation on the wideband that I want says that the sensor should be located at least 12" back of the turbine outlet. Obviously with my old exhaust setup there was only about 8" of exhaust after the turbine total. So it had to be redone.
I'm kind of glad that it turned out that way anyway though because I love making exhaust and intercooler piping stuff. I think it looks much cooler this way.

The reducers I made by taking the 2.5" pipe and v-cutting a section out to neck one side down to 1.75" The main body of the "muffler" was done that way as well. Overall I'm really pleased with the look and can't wait to hear how this thing is going to sound! :banana

On with the pictures:













As you can see I've got a lot of welding left to do here :onfloor
The swingarm clears the exhaust perfectly throughout its stroke, and I made a nice little exhaust brace that unbolts from the subrame.

Take a look, let me know whatcha think?

Also, I don't have it yet, but this is the headlight unit that's going on this thing:


Mine will be black not blue, but I might modify it a bit yet, we'll see.

I know a bunch of people won't like this headlight. Mainly because I don't like any of the other headlight options out there. I've literally tried about 100 different setups in my head, and none of them looked right. Maybe if I could get my hands on a brand new Ducati Streetfighter headlight it'd be different. But I can't.

Anyway, thanks again for sticking with me, and hopefully things will move forward at a better pace now.

Sky

[bigdaddyvtec]

 

[PhilStubbs]

good to see some progress again