Topic: New bike project.....Yes this one is going to be turbocharged, It rides! (Read 67476 times)

96turboracer · « **on:** May 13, 2009, 01:49:39 PM »

Hey guys, figured I'd post up my newest bike project.

Initially I wanted to use a Yamaha Road warrior engine, but at $2000 and me still not working, that became slightly out of the budget. So I got another XS650 engine and frame for $150.00 eventually I want to showcase both my chopper and this bike together to show the extremes you can go to with the same platform.

Specs and Goals:

1977 XS650 frame/engine the engine will remain mostly stock, just rebuilt.
I'm switching the engine over to fuel injection. It will be run by Megasquirt controlling fuel and spark.
The motor will be turbocharged and intercooled- if my #'s are correctly calculated, I should be getting about 88hp out of the engine, so maybe 75-80 at the rear wheel.
ZX6R front suspension and bars
Buell swingarm and rear shock
Frame will be 70% my own construction
Bike will have all the same specs as a modern sportbike regarding the rake/wheelbase/ect... However, it will be taller than most sportbikes. I've got really long legs and I like taller bikes, plus, I want to keep people from wanting to ride my bike.
Wheels will be f2/f3 style
Full brakes from ZX6R
Custom subframe and tail section of my own design
Buell headlight and windscreen
Suzuki GSXR gas tank
bunch of other stuff I'm forgetting.....

Pictures:

Tail section I molded from foam and fiberglassed:

swingarm, tank, and tail section:

Buell swingarm, was initially purchased because the warrior engine is a right side drive. I still wanted to use it, so I'm filling in the right side, and cutting a space for the chain on the left side.

Made some paper templates:

Cut the pieces out and welded them up. This is my first time working with aluminum, it's pretty fun.

smoothed the welds, the piece should be welded in place pretty soon:

Here's the frame I started with:

here's what's left:

quick mockup-

Frame progress:

That's what I've got so far. I know it looks like there's a lot of space around the engine in the frame, but the turbo is going back there, along with the intake manifold. The intercooler will be mounted vertically on the downtubes.

I've got a mockup turbo coming in the mail, also my blow off valve and Buell rear shock.

This is going to be a really involved build I hope you'll have as much fun following along as I have building it.

I'm sure I've missed a bunch of stuff, so if you have any questions feel free to ask.

thanks
Sky

Just after I wrote this I started thinking about something else on the bike and went down to look at it.

It's funny how the mind works sometimes. I was down looking at the bike thinking about another aspect of it, when I looked at my other bike, and turned the bars.

There's no way I could turn the bars on this bike with the frame the way I made it!!! Haha

So I had to cut the top bars and redo the front section so the forks would have the room needed to turn.

Old version:

New version:

It's a little tough to see what I did from those pictures, but at least now I can turn....

onlyflash944 · « **Reply #1 on:** May 13, 2009, 01:54:02 PM »

turbo?? can't wait to see it. you do excellent work

dvst8r · « **Reply #2 on:** May 13, 2009, 04:33:04 PM »

Good stuff, looking forward to this build.

brine04 · « **Reply #3 on:** May 13, 2009, 06:13:32 PM »

Your projects rock Sky. I can't wait to see this one come together.

96turboracer · « **Reply #4 on:** May 14, 2009, 08:26:59 PM »

Got my rear shock today, sheesh, this thing is a lot bigger than I expected. Really nice part though.

dvst8r · « **Reply #5 on:** May 14, 2009, 08:53:22 PM »

Looks good, I definitely don't have the vision to build something like that. Keep bringing us the updates!

CSaddict · « **Reply #6 on:** May 14, 2009, 09:06:56 PM »

Love your build threads Sky. :yes:

weirtech · « **Reply #7 on:** May 14, 2009, 10:41:15 PM »

awesomeness.

crxvtec91 · « **Reply #8 on:** May 14, 2009, 11:52:20 PM »

Very nice, what turbo you plan on running?

96turboracer · « **Reply #9 on:** May 15, 2009, 01:33:29 AM »

Quote from: crxvtec91 on May 14, 2009, 11:52:20 PM

Very nice, what turbo you plan on running?

14B

It was really the best choice I had. Suprisingly, the compressor map isn't that much different than a GT15, and I can pick one up for way less.

It's still a little big for my application, but if I were to try to size the turbo perfectly I would have to spend a lot of money. So this should work.

I bet that's the first time you've heard someone say a 14b is too big

It was really interesting going through all the compressor maps looking for the right turbo. You see how so amny factory turbocharged cars have really terribly matched turbos. They give quick off the line punch, then the compressor efficiency goes through the floor, and then people turn up the boost on them and it really goes out the window! Craziness...

SloS13 · « **Reply #10 on:** May 15, 2009, 09:16:43 AM »

holy balls this is gonna kick ass!

Have you considered a Smart car turbo?

96turboracer · « **Reply #11 on:** May 15, 2009, 01:17:53 PM »

I've never seen one, I'll try to look up the compressor map and see what the availability is.

Emperor · « **Reply #12 on:** May 15, 2009, 01:33:30 PM »

Quote

holy balls this is gonna kick ass!

Have you considered a Smart car turbo?

;DLOL good luck

header and turbo are one piece

dvst8r · « **Reply #13 on:** May 15, 2009, 01:46:48 PM »

Smart Car turbo is too small, it runs out of steam at not much over 40hp, it would be good for like a 125cc - 250cc bike.

Oh and as far as it being one piece not a big deal, you just cut off the manifold at the collector, and weld on a v-band flange.

96turboracer · « **Reply #14 on:** May 15, 2009, 02:09:23 PM »

I already purchased a pretty beat 14b off of ebay over a week ago. Should be here any day now. I don't know if it's going to be salvageable or not, but even if not it's going to be a good mockup turbo. Got it for $30 shipped hah, probably cost the guy almost the whole amount just to ship the thing.

dvst8r · « **Reply #15 on:** May 15, 2009, 02:11:18 PM »

Nice, iirc they are pretty cheap to have rebuilt as well.

glustic · « **Reply #16 on:** May 15, 2009, 10:11:21 PM »

Nice. Cant wait to see the final project. Keep updates coming!

96turboracer · « **Reply #17 on:** May 16, 2009, 12:34:45 AM »

Not much today, I got my blow off valve in-

Only other thing I did was shape some tabs for the subframe mounting and tacked them in place. These I used some welding rod to simulate a platform to set the tail on so I could get a better idea what it's going to look like. Also, I think I've pretty much got the height set for the swingarm so I'm going to start building the upper mounting point for the shock.

Not much I know, but thanks for looking anyway

Sky

Henry · « **Reply #18 on:** May 16, 2009, 09:40:25 PM »

The dual tubes on the upper part of the frame remind of the Triumph Speed triples. The bike looks good. Mad props Sky!

shogun · « **Reply #19 on:** May 17, 2009, 04:02:23 PM »

nice project looking forwart to seeing it finished :yes:

90boostdaccord · « **Reply #20 on:** May 17, 2009, 06:29:36 PM »

this project is money. awesome fab work buddy

7808 · « **Reply #21 on:** May 20, 2009, 06:03:04 PM »

looks good.

it will be interesting to see how that motor spools that thing and how it handles boost. i seen a 750 bigbore kit that makes the stock motor like 50hp / 90ftlbs tq :yes: are you what kind of throttle body set up u planin

96turboracer · « **Reply #22 on:** May 21, 2009, 04:08:31 AM »

Change of plans on the turbo, the guy I was getting the beat 14B from didn't come through, so I found another option. It actually has a better compressor map than the 14B and I won't have to rebuild this one, so it's all for the best. I'm getting a K04 turbo from an Audi TT. Pictures will come next week as I won't get the turbo until Thursday of next week.

The throttle body I'm going back to my roots

I'm using the stock 49mm TB from a Dodge Neon

I'm also using stock Neon 19lb injectors, Don't need a whole lot for this setup.

One final note, I'm moving back to the coast this weekend and setting up shop in my dad's garage for the time being. Getting everything settled into a much smaller space sucks, and I suspect progress might be slow for a bit as I'm also trying to complete my physical training for becoming a firefighter. I hate when life gets in the way of my projects! Anyway, Hopefully I'll have a somewhat decent update for you guys soon enough.

Later
Sky

dvst8r · « **Reply #23 on:** May 21, 2009, 11:19:15 AM »

K04 might be a little large, I would think a K03 would be right about perfect though. Depending of course on your power goals.

96turboracer · « **Reply #24 on:** May 21, 2009, 11:36:30 AM »

From what the compressor maps looked like it seemed the K03 and K04 had the same efficiency range, just the K04 is a more flexible turbo.

dvst8r · « **Reply #25 on:** May 21, 2009, 12:00:39 PM »

Lol, I guess we are both being a little vague, as there are a number of turbo's in each family. Sounds like you did your homework in any case.

Maybe I missed it but what are your power goals for that bike. Some of the K04's are good for 200whp+ (strung right out) That and (2) Neon Injectors are only good for about 60hp.

96turboracer · « **Reply #26 on:** May 21, 2009, 12:55:27 PM »

88hp for the engine, so maybe about 75-80 at the rear wheel.

I ran the #'s through an injector calculator and it gave me the 19lb ones. I thought it seemed a little on the low side as well, but I got the injectors for crazy cheap so it doesn't really matter if I have to move up a bit.

dvst8r · « **Reply #27 on:** May 21, 2009, 01:00:21 PM »

Quote from: 96turboracer on May 21, 2009, 12:55:27 PM

88hp for the engine, so maybe about 75-80 at the rear wheel.

I ran the #'s through an injector calculator and it gave me the 19lb ones. I thought it seemed a little on the low side as well, but I got the injectors for crazy cheap so it doesn't really matter if I have to move up a bit.

If you get to the point where you need more inj, I am sure there are a few nogs around this place that have some 440's (42lbs) or something similar on the cheap.

96turboracer · « **Reply #28 on:** June 07, 2009, 12:17:39 AM »

OK, not too much to show you guys lately, been finishing my move to the coast, setting up shop in my Dad's garage

I got my new rear wheel in the other day, a couple mockup pics:

Got my turbo in the mail too, slight change of plans there. The original 14B I was supposed to get didn't show, the guy refunded me, and it worked out well actually because it made me look around some more. Got an even better setup with my new choice K04 turbo from an Audi TT:

size comparison:

Here's the most likely turbo mounting position:

I also got started on my flanges for the intake manifold I'm making. My dad had some aluminum in his shop so I started drilling:

Think it's thick enough? :yes: 1/2"

obviously they'll be shaped more eventually, but that's the basic idea.

I should have my front wheel and forks showing up soon, as soon as they get here I can start setting up the ride height of the bike and it'll start looking a little more complete.

Thanks for looking guys....
Sky

dvst8r · « **Reply #29 on:** June 07, 2009, 01:31:28 AM »

Nice, I see you have the rear swingarm all welded in now too.

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Author Topic: New bike project.....Yes this one is going to be turbocharged, It rides! (Read 67476 times)