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[dvst8r]

I definitely thought about it, but I'm just not confident enough in my aluminum welding to have pulled it off.

Only one way to get there.

[robus]

I would have cut off some of that ridiculously long compressor discharge tube, used some aluminum and made some tight whitey bends right at the compressor. It probably would remove 8" - 12" of intercooler tubing. At least half of the long straight piece, and the whole bottom turn.

I definitely thought about it, but I'm just not confident enough in my aluminum welding to have pulled it off.

You could still cut that compressor discharge and just tack it in a few spots at the end, use the rubber coupling and then shorten the piping.
What I wanted to say though is, fantastic work! This is getting ever more awesome. Can't wait to see it done

[Ntrain2k]

I love the frankenstein look of that motor setup!

[96turboracer]

back to the progress pics:

I've been having a really tough time figuring out how to mount my rearsets. So I decided to take advantage of the factory mounting points that I had left in place (I'm glad i did that) I got a set of factory pegs:



These were a touch too long, so I took about four inches out of them





This puts the pegs in a perfect spot. I'm going to cut those pegs off and use them on my chopper redesign this winter. These mounting brackets will become the base for my ZX6R pegs.

I also got to use my lathe for the first time! When I first tried it, the lathe wasn't spinning true, there was a tiny wobble in it, which of course makes a lathe useless. Anyway I started freaking out a bit, but then I tried to tackle the problem logically. Eventually I pulled the chuck off, and found the backing plate where the holes were drilled had some small burrs still in place, so I used the lathe to face it up a bit, put the chuck back on and Voila! works like a champ.

Started making my fuel rail injector bungs. I don't really have a before shot, but just imagine some 7/8" bar stock. I cut down the outside to about 3/4", then drilled the center and bored it to 17/32" Then I chamfered the end to ease the o-ring entry. I still need to polish the inside a bit, and take some of the edge off. Overall though I'm extremely pleased with how they turned out, and I'm having a blast with this new tool.



Tapping 1/4" plate is a pain in the butt:







Still some finishing work needed before I weld it up, but it's one step closer, a million to go.

Thanks for looking
Sky

[onlyflash944]

What lathe?

[Joseph Davis]

What lathe?

[turbob16hatch]

He posted up he got a mini table top lathe on h-t.

[dvst8r]

What lathe?

Haven't gotten any new work done to the bike, but I did get a new tool!



So first off, I realize it's a harbor freight lathe. I got it barely used for a really good price, and for the type of work I expect to do it should be great. I'm really happy and can't wait to try it out.

You nig nogs, it was only back one page.

[Joseph Davis]

There are huge cult followings for those things.  As well as writeups on how to fabricate everything and redo the entire lathe to the point it's extremely precise - also great machinist training for the homebrew crowd.

[turbob16hatch]

There are huge cult followings for those things.  As well as writeups on how to fabricate everything and redo the entire lathe to the point it's extremely precise - also great machinist training for the homebrew crowd.

So this is something that would work for someone trying to get into some basic machining. ( ie: not waste $2-5K on a big machine when you don't even know how to use it, lol)

[TunerToys]

Nice work on the rail!  Tits.

[Joseph Davis]

There are huge cult followings for those things.  As well as writeups on how to fabricate everything and redo the entire lathe to the point it's extremely precise - also great machinist training for the homebrew crowd.

So this is something that would work for someone trying to get into some basic machining. ( ie: not waste $2-5K on a big machine when you don't even know how to use it, lol)

Yes.

This site now has some gay ass "premium content" section with a lot of the articles shuffled in there - a few months back it was a huge free resource with really good shit.  Anyway, this much of it appears unmolested, and it's the parts about rebuilding/modifying the lathe in order to make it very nice. 

http://www.mini-lathe.com/Mini_lathe/Modifications/modifications.htm

I'll run a web spider on it today/tomorrow, try to maintain an archive before that shit dissappears.

[96turboracer]

Man that's the truth on the lathe. It's funny after I got it I started looking around and it's amazing how many sites there are covering upgrades to those things. There's even several people who have converted them to full CNC.

Rail is welded up and installed. I'll get some pics later today, Looks pimp.

[96turboracer]

So I've discovered the inherent flaw in using pie cuts for everything. Besides tons of welding that is. All the heat from welding, and all the little gaps added together means a lot more opportunities for the metal to pull. I finally welded up the exhaust and the turbo manifold. The turbo mani pulled almost a quarter of an inch, so I had to cut it apart again and add in a section to get it back where it needed to be. Whew, that was a lot of welding







Also I welded up the fuel rail and installed it. I still need to figure out some mounting tabs for it, but it just looks so cool in there I had to take a few pictures!



It's a tight fit for sure.



I'm optimistically about a month and a half away from starting this thing up, got to start checking things off of the list so I can accomplish that.

Welding up the intercooler piping is next.

thanks for looking
Sky

[robus]

That's just awesome  :yes:
Cant wait to hear that sound

[dvst8r]

Looks good sky, I wish I had your patience. Pie cuts drive me nuts, as I always want things done yesterday, and hate how much time they take.

I am looking forward to seeing some videos of this thing running.

[malichite]

Donky Dick Down Pipe

Front Fucking Page!!!!

[92CXyD]

Donky Dick Down Pipe

Front Fucking Page!!!!

I second that. ;D

That is a hell of a lot of welding. I do not know if I could be patient enough for that. ;D

[DasPoop]

thats going to sound crazy a vertical twin and a turbo what could be better.

[toyolla86]

is it a 2 stroke. if not why the hell is that exhaust pipe all coned out

[PhilStubbs]

My thought is to look like a muffler. Being turbo it won't need one, but it looks like it has one.

[dvst8r]

Update.

[Joseph Davis]

Update.

Where??

[96turboracer]

Updates are coming guys, I'm working on this again, trying to get the motor started. Wideband should be here in the next couple of days, got my trigger wheel and vr sensor as well.

[PhilStubbs]

You are gonna have one serious right leg after all of the kick starting and making the megasquirt run. Lol

[96turboracer]

Hah, yea no kick starting this one. I'm going to install the factory starter for this bike.

[DasPoop]

curious where your running your trigger wheel off of. are you using the cam more specifically where the factory points mount? Just curious about the setup.

[96turboracer]

Working on that now. The plan is to mount my 36-1 wheel to the bolt on the crankshaft. It'll sit outboard of the rotor/brushes.

[PhilStubbs]

Hah, yea no kick starting this one. I'm going to install the factory starter for this bike.

i dont know why i thought this was a kickstart only engine

[DasPoop]

Working on that now. The plan is to mount my 36-1 wheel to the bolt on the crankshaft. It'll sit outboard of the rotor/brushes.

Gotcha ok so your just running a crank rather than cam based system. If it was to be cam based i would ask how many miles are on the motor and how you were going to deal with timing chain stretch.

Gonna be a sweet setup