Project; Turbo GSXR Slingshot

[Danm54]

Im crap at updating this thread!


I have an engine in the bike now, standard 1100 W with a 1.5mm spacer plate under the barrels, if my math is correct it should take the comp ratio to 9.1:1.

The engine is supposed to be a good low milage one but there are signs that its dropped a valve at some point probably farily recently, dinks in the piston top and head etc, the bore looks ok and the valves look ok too but im not holding out much hope of this one lasting that long!

Should get me up and running though and be suitable to test if my set up works or not.


So im starting to build the bike up to a stage where it'll run, current issue is fitting the plenum, with the injectors in I now can't put a bolt through the top holes as you can see here

I'll have to put studs in the head, if I do that though I cant fit the plenum on with the fuel rail attatched so I have to take it off, but it wont fit on with the plenum in place as the frame is in the way!

I may have to slot the top holes so the whole assembly will slide on sideways.
I also need to skim the flanges on the plenum as they've warped quite a bit with all the welding, times like these is when Im glad there's a mill in the shed!


I need to have a look in to stick coils, Ive recently fitted one to the DR and its solved quite a few starting problems, it also likes the wet better now!
There isn't a lot of room above cylinder 1 and 4 as the frame goes over them but if I can find something to fit in then it could save a few problems down the line.

Once Ive sorted that problem im getting real close to making the loom, I have a load of cable here ready and a massive wedge of paper on how to wire the ECU etc!

Hopefully I may get this running in the new year!

 

[Danm54]

Got my up pipe finished off tonight

Also finished the exhaust from the turbo, got the lambda sensor nicely tucked away around the back!

I'll take these down the local fabricators in the morning to be tigged up.


Got a list together of all the fuel line fittings and coolant hoses etc so I should get them ordered tomorrow.

 

[Danm54]

Its getting there! Seems to go for ages with very little change then I make some big decisions/purchases and make a lot of progress in a short space!

Ordered many pounds worth of coolant and boost hoses and nearly everything for the fuel lines, they came on friday.

Got some ally for spacers etc and a few fittings to start the oil lines.

Missed out on picking the exhaust stuff up friday so I'll get it monday.

Should be some good progress in the next week or so.

 

[Danm54]

Exhaust fitted, looks immense!

Some shiney an6 fittings for the fuel line, managed to get 3 matt 90's in my order, not sure how it happened but they'll be going back to be changed.

And this is just about my fuel line layout (without pipes yet), some things haven't gone as I'd expected due to a serious lack of room but it'll all fit in, just need to sort a fuel tap out!

 

[Danm54]

More progress!

Been making up a few fuel lines, quick guide if you fancy having a go,

Buy some vice jaws, £15 but worth every penny!
Clamp the nut in there and push the hose in untill it hits the threaded part of the nut, if you've taped it and cut it cleanly it'll go in easily

Put a little oil on the thread of the fitting

Wind the fitting onto the nut making sure the hose doesn't push out the back of the nut

Tighten with a spanner, I stopped when the flats lined up cause it looks so much better

And you have a nice fitting thats never going anywhere!

Made up all the hoses I can, got a filter and check valve coming tomorrow so should be able to do a few more.

Made up a tee to join the pipes coming off the head (you can see in the bottom left of the above pic) as I cant find anyone that does an aluminium 19mm tee!

 

[Danm54]

Changed it!

Was getting to a point where I was fast running out of room and I couldn't figure out a neat way to connect the flow and return to the tank, so I pulled everything out and moved the pump and regulator!

As I'm going with stick coils then I'll no longer need as much room in the front of the frame so I dropped the fuel pump in front of the engine, the regulator will sit on the breather but further forward.
Also gives me space to put a filter between the fuel pump and the fuel rail, just got to alter a few pipes!

Got the return from the rad sorted too.

 

[Danm54]

Got a heat shield made up tonight, will space the pump and reg off the engine.

.


Mounted the reg too, worked out a nice pipe route

A couple of people on OSS have expressed a concern that the pump might get a little too hot where its now mounted, I may look into other places to mount it if they can convince me but im struggling to see how it could make that much difference.

 

[Danm54]

Made a heat shield but apparently its the heat in the general area that will cause problems, I've now moved it behind the right fairing, high up by an intake, just need to mount it.

Stick coils are here, last few fuel line fittings should arrive tomorrow so I'm close to loom making.

 

[Danm54]

So this is the new set up, although I've altered the check valve on the return as it was a bit too tight to fit the tank on!

Stick coils are in there too, perfect size!

 

[Danm54]

Whilst I'm waiting for my fuel pump mount to be welded up I've cracked on with the undertray, not been looking forward to this as I wanted the tray to be fixed and the seat and plastics removable for access to everything.

As it happens my hours of mulling over ideas have paid off and its looking good!

Trimmed the plastics back a little and got a tray made up that'll attatch to the underside of the subframe, the plastics are easily removable.

Ive folded the rest of it in so theres just a little trimming here and there required but its looking good!
I can see some fibreglassing coming on before painting!

 

[Danm54]

Always impressed by clever people out there doing stuff to things that supposedly cleverer people at manufacturers could never dream up

What you doing for fuelling? Carbs, microsquirt, emerald, something else?

Thanks

Gone with the Microsquirt V3 running 4 injectors in the plenum and a single TB before the turbo. Oldskool draw through with a modern twist!


Finally got the fuel lines finished!
Got a quick disconnect on the flow and a check valve on the return so I can take the tank off without draining it.

At this it only just comes off without touching the frame!

The pump is mounted in its new cooler space

And nicely hidden by the fairing

Got some fans here for the oil cooler, had no choice but to go with PC fans, well, more server spec actually.
They run at 4100rpm and shift 90cfm, they're also 50dB each!

Will be fitting those this week all being well.

 

[Danm54]

More progress on the undertray, all cut and shaped to size now, just got to mount it up.
Will have a bit of altering to do on the fibreglass seat unit so I'll bring the edges down to meet the undertray. The tray is tight to the subframe already so not chance of it going up a little unfortunately.

Got the bracket for the rear light made up too, just got to sort out a number plate mount and bolt/weld it all together.

 

[Danm54]

This looks amazing! What sort of insurance cost would you be looking at with a turbo on a bike though? Or is is just for track days?

This is definatly a road toy! Too much time, effort and money for a track bike.

Not had a quote but others get insurance for £200-£300, obviously you have to go to the right insurer but I dont think it'll be too bad.

 

[Danm54]

Santa pod is most certainly on the cards! As are a few track days I think.

The shed is the landlords, kinda lucky to have this at the bottom of the garden really!


This is still being worked on, just little things happening and moving/altering/finishing a few things ready for wiring, I want as much as I can in place before I start wiring.

Got the number plate mount sorted though, will eventually get all the parts of the undertray welded together.

The clocks bracket got made too,

Thats been cut and the final bit of welding is being done this week along with the new rad mount, made one out of stainless that has the fuel pump mounted on it and the fan is also mounted to it as well. Another thing I've recently bought, a mega powerfull 5'5'' fan!


Also had a crash course in turning, made a bush for the AIT sensor, this will now sit in the plenum rather than in the silicone hose before it, just couldn't get anything to fit.
Not bad for my first turned piece eh?

Also turned a couple of hats for the ends of the throttle cables, the ones that came in the kit (right) just didn't fit with the Busa switch gear so I turned a couple up. These literally just finish the the ends of the cable off and sit inside a plastic adjuster.

Should have some more pics of finished pieces soon!

 

[Danm54]

Is that pump mounted to the forks? surely that's never going to work?

Its mounted off the rad bracket. I've since made a single bracket that holds the top of the rad, the fan and the fuel pump.

 

[Danm54]

Got the fan mounted,

Very tight fit when its mounted but it clears everything, will just have to watch the clearence on the headers when they warm up.

 

[Danm54]

I know nothing about bikes.

What sort of speed will this do? Acceleration?

Not sure, I'm hoping to get 200bhp+ out of the final build though so I'm sure you can imagine the acceleration!

 

[Danm54]

What sort of weight are you expecting when its all done?

Again I'm not sure, the standard 1100W is 221kg dry but I'm using a different frame, seat unit etc.
I'd like to think it'd come in under 320kg all in.

 

[Danm54]

Bit of an update from the last few weeks.

The plenum has been skimmed so its in line where it bolts to the head, welding had warped it by ~1mm.

That's all been made up with the injectors, sealed and bolted to the head. As I can't fit a bolt in the top slots of the plenum due to the injectors I had to turn down some cap nuts and locktite a stud into them, even now it only just went on!




I can't be the only one that drools at this!




Air Intake Temp sensor, cant get much more in the air flow than that!






Got my throttle cables finished too, some Yamaha cable ends fit nicely onto the throttle body. Only got the screw pins on to check it worked, got some soldered ones to go on now,




Turbo is in, boost hose is connected and the throttle body is in place. That's a nice straight intake that's gonna sound awesome!

 

[Danm54]

Please put a filter on that...for the sake of children and small animals!!!

Nooooo, this is gonna eat children and small animals for breakfast!!

I actually haven't figured out where the filter is going yet, will probably be a billet air box type thing with a panel filter looking down.


Had a few hours on it today as we've got no work (which is actually a bad thing!)

Made this out of 20mm solid ally round.
Will split the boost pressure to the MAP sensor, boost gauge, fuel pressure regulator, wastegate and water injection switch plus one spare and the inlet!




Will sit about here, not with the P clip though, got some ally P clips on the way!