Project; Turbo GSXR Slingshot

WARNING, THIS POST CONTAINS PICTURES OF ENGINE COMPONENTS IN DESTRESS!!


Intake valves and piston tops are glazed heavily, I'm sure someone knows why this has happened but I can't be arsed to think it through now.










Moving onto the valves now, either get all the bad news out the way or find a positive...
 
The outer part of the valve doesn't touch the head though, its only the black line thats been seating the valve.
I was under the impression that the outer angle of the valve should seat on the head?

Just priced up the pistons, £470.
 
The valve seating has been explained on another forum and you're right JamesRJ, it seats on the centre 45 degree angle with the other angles improving flow.

I also checked the wastegate bleed valve to see what pressure it opened at, it was replaced and set by John. Got to 2 bar and it hadn't budged.
Opened it up and the bolt was wound in until it touched the ball, wouldn't open at any pressure like that.
 
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Things are still moving forward, new pistons arrived and are with a set of barrels waiting to be bored out.



The old set were bored too big for the pistons, piston to cylinder clearance according to MTC should be .002" - .0025"

Head has been cleaned up and checked for flatness on a CMM, its 5 microns out so it pretty damn good.

Temps creeping up on the dyno mean I need a bigger rad.
Only way thats fitting is new header design, so after a few hours trying different ways I pretty much started again.


Didn't like this one




Got rid of the lower bend and went with this design




Ordered more bits...




Then its cutting, grinding, linishing and welding




 
Only 316 tube and fittings I could find were on ebay.

V band clamp was from Darkside Developments and is really nice, cheaper and much better quality than those on ebay.

Got the number 3 header in now but had a mare with the welding as I didn't get the fit tight enough, then broke through the pipe tidying the blend up inside! Its ok but its left its mark.

Kind of ruins the lines but there's a frame to avoid...

 
Thanks, it's not bad but I think I could do better if I practiced more and maybe had a bit of tuition. I'm happy with it though.

Rebore is done so I need to sort the pistons out to remove potential hot spots then cc it again and work out comp ratio.
 
Finally got time to finish the headers



Got a full size rad in there now and it should clear the front wheel easily



Pistons are with a mate getting the sharp edges around the valve pockets removed, then it'll be rebuild time.
 
Shirley is reserved for 'those nights' :eek:

As said above, its common for IL4's and my gsxr 1100 with an Akra system runs closer. Only an issue when stationary or slow riding.
 
Made an adaptor up to get from the twin 38mm to the 51mm

Its not going onto the v-band but its good to hold it in place while its tacked, got some trimming to do to move it up as well.

 
Been slow on this lately but its finally moving.

Cc'd the piston and bore, got a 1.5mm spacer under the barrels instead of dishing the pistons this time.



If I use a .018" thickness head gasket it'll give me 9.14:1 comp ratio with 1.77mm squish.

Little comparison between the new and old pistons, both MTC turbo but the newer ones have much more meat.



Installed the pistons in the barrels on the bench the got a mate over to help hold the barrels up whilst the gudgeon pins and buttons were installed.
Was a little tricky but went well and easier than trying to get 2 pisons at a time into the barrels.



More updates once I source a head gasket.
 
Not sure on piston weights actually, didn't compare standard to the 2 MTC ones but there's a good amount of extra material on them.

Head gasket should be here by the end of the month. Ordered from Performance Unlimited, Cometic make them to order and ship them out every fortnight. Could have possibly got it quicker but I've used these before and don't mind waiting.

Once the engine is back together I'll finish the headers off. Looking at getting a Tial Wastegate as well, pricey but I can spec a 12psi spring and not have any worries with boost controllers.
 
Well Monday was build day but it didn't start until mid afternoon!


Got the head on and then spent forever dialing the cams in. The spacer under the barrels threw things out a bit and it took a bit of working out to get the cam sprockets right so the adjustment range worked ok.


Got the exhaust cam at 110.5 degrees which is spot on but the intake cam keeps falling 1-2 degrees out either way.


Left it for the night to re-check the degree wheel and exhaust cam in the morning then have another go at the intake cam.

Cams dialed in finally, the degree wheel had moved a touch so reset it and double checked it all once I'd finished.


Intake lobe centre is 108.25

Exhaust lobe centre is 110.5


Got a few other bits bolted on but hit a problem with the plenum, the o-ring seals are made of cord and have shrunk slightly so there's now a gap. Measured up and ordered some new ones, hopefully they'll fit.


Can get the headers back on though and finish them off.
 
Exhaust is nearly done, main parts done and are now tacked up, just the wastegate to connect in.

Yes, its a terrible pic but the shed lighting is all wrong from this angle :p

 
It comes off with a bit of room to spare.

Have to remove part of the exhaust on the other gsxr with an akra system so avoiding that on this bike.
 
Finished welding the v-band clamp, thats the exhaust pretty much done. Need to decide on a wastegate, think I'll go for the v-band Tial as its only a few quid extra than the flanged Tial.

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Plenum and turbo are fitted along with most of the wiring. Can't fit the rad yet as the headers will have to come off for welding the wastegate flange on.

Can sort out the breathers and look at making a catch can until the wastegate arrives.
 
New Tial wastegate arrived, finally earnt enough money to justify buying this!

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Fits good and a fair bit smaller than the old one. Plus v-bands which everyone loves!

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