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Project; Turbo GSXR Slingshot

Discussion in 'Biker's Cafe' started by Danm54, May 13, 2011.

  1. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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.

    [​IMG]

    [​IMG]

    [​IMG]

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    Moving onto the valves now, either get all the bad news out the way or find a positive...
     
  2. JamesRJ

    Wise Guy

    Joined: Dec 9, 2002

    Posts: 1,495

    Location: Somerset

    Humm looks like its been detonating :( I feel your pain
     
  3. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    It appears the valves are only seating on one of the angles as well.

    Certainly haven't got a big surface area to seat on.

    [​IMG]
     
  4. JamesRJ

    Wise Guy

    Joined: Dec 9, 2002

    Posts: 1,495

    Location: Somerset

    The looks right tbh, the smaller the seat the better the gas flow, the angles are also there to improve flow
     
  5. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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.
     
  6. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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.
     
    Last edited: Sep 24, 2016
  7. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    Things are still moving forward, new pistons arrived and are with a set of barrels waiting to be bored out.

    [​IMG]

    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

    [​IMG]


    Got rid of the lower bend and went with this design

    [​IMG]


    Ordered more bits...

    [​IMG]


    Then its cutting, grinding, linishing and welding

    [​IMG]


    [​IMG]
     
  8. Fireskull

    Sgarrista

    Joined: Oct 31, 2006

    Posts: 9,657

    Location: Eastleigh / Winchester

    Looking good! Nice welds too :)

    Where do you order your tubing from?
     
  9. MowyTone

    Mobster

    Joined: May 4, 2009

    Posts: 3,366

    Location: Southampton

    Was looking at the welds as well, good job! A sexy looking shape on those pipes as well
     
  10. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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...

    [​IMG]
     
  11. Diddums

    Capodecina

    Joined: Oct 24, 2012

    Posts: 19,536

    Location: London

    I must say that you're a pretty damn good welder.
     
  12. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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.
     
  13. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    Finally got time to finish the headers

    [​IMG]

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

    [​IMG]

    Pistons are with a mate getting the sharp edges around the valve pockets removed, then it'll be rebuild time.
     
  14. Diddums

    Capodecina

    Joined: Oct 24, 2012

    Posts: 19,536

    Location: London

    Shirley those headers are just going to heat the rad up?
     
  15. Fireskull

    Sgarrista

    Joined: Oct 31, 2006

    Posts: 9,657

    Location: Eastleigh / Winchester

    Theres barely much clearance behind most radiators to the headers on most IL4's.
     
  16. Diddums

    Capodecina

    Joined: Oct 24, 2012

    Posts: 19,536

    Location: London

    That's a good point. I suppose if you're on the move the heat just gets blown back, just seems a bit wrong to me, but then I don't design bikes or turbo them to an inch of their life so what do I know :p
     
  17. .one.

    Mobster

    Joined: Aug 1, 2006

    Posts: 3,655

    I am not sure what the op name is but I don't think it's Shirley ........ :p
     
  18. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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.
     
  19. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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.

    [​IMG]
     
  20. Danm54

    Wise Guy

    Joined: May 20, 2009

    Posts: 1,771

    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.

    [​IMG]

    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.

    [​IMG]

    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.

    [​IMG]

    More updates once I source a head gasket.