Project; Turbo GSXR Slingshot

Not really, I know nothing about bikes! :o

I'm assuming a 0-60 (if thats even how you measure bikes) of sub 5 seconds?

Like Persil said, most will do sub 3 sec with the right rider on board.

This has an extended swinger which will help off the line and hopefully help keep the front end down when accelerating in gear, its not extended too much from the original though so it shouldn't hamper it too much in the corners.
 
Started wiring last week, had about 4-5 full days on it so far.

This was at the start, just ECU cables in there!




Trying to braid as much as I can as well, bit of a long process but looks nicer, the pic is just for the ignition amp module, the switch gear, light looms, ignition switch and clocks loom is all braided too.
You can see the main loom in this one too, got some 20mm woven sleeve and been fishing the wires through that, again it takes time but keeps things nice and neat.





I've got part of it powered up too, clocks power up and the front lights work!
I'll get some more up to date pics soon.

:)
 
How long til completion do you reckon? (This thread really has piqued my curiosity and it's frustrating me :D :D :D)

I'm gonna say about 2 weeks until its all powered up properly, the sensors need to be wired one at a time, calibrated and checked on a pc so that'll take a few evenings!

It's not that far off running but getting it on the road will take a bit longer.
 
Just to give you a little idea of my headache!
Fuse box is sorted hopefully, just got a couple of 250ma in line fuses to put in for the ECU and the data logger.

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This is where the fun happens! The switch gear is done, clocks are nearly there, just got to sort the fuel light out which isn't actually that simple. Also got to look into getting rid of the check light as its permanently on because its not getting a signal from the stock ECU.

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Then it's just sorting my 'arm' switch for the compressor, water injection and air shifter, the front indicator loom which will have the fuel pump wires as well and the fan and horn wiring.

Then I get to power the ECU and start connecting sensors and injectors!

Its taking ages to sort this out but its getting there.

:)
 
The ECU is finally powered up!

Bought myself a bargain laptop, at least 15 years old but it has a working com port. Just needed a new screen and a little RAM upgrade. Cost me £47 in total.

Runs Tuner Studio just fine.


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coolant sensor and air intake temp sensor are connected, coolant one needs calibrating but they show up and work.

:cool:
 
Well the under seat oil cooler is piped up, wasn't too bad in the end really. The lines up there are pretty well hidden.
The turbo oil drain is sorted temporarily as I need the clutch cover from WSR back.
Its filled with oil, the cooler is full and the turbo feed is bled up.

The Lambda is all sorted bar a cable I need to shorten but I'll leave it as it is for the initial fire up. The last sensors are in and wired, fuel pressure is set and there's fuel in the tank.

Just waiting for Tiff to make the 36-1 trigger wheel then I'm ready to fire it up, watch this space...

:D
 
Found a couple of errors I made while setting up the fuel injection, firstly I'd entered the wrong injector size and secondly I'd got the timing a little out, with those corrected it no longer smokes and sounds much sweeter!
:cool:

 
Ive got some RAM air filter sheet on the way, 15mm think with a stainless mesh behind it. Will make up a temp filter to see how well it works and see if it gets in the way. Its easily accessible so not hard to keep clean.

Few pics to catch up on, my trigger wheel being made


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This shows the run if the oil lines to the cooler, they've gone in really well and very discrete


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Also cut some vents in the undertray for the cooler fans, got one at the bottom drawing air in and the other 2 blowing/sucking through the cooler.
Need a lot of tidying up but I'll see if it flows enough air to keep it cool first.

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Also set the height and made up some dog bones, also still to be finished off as long as they're the right length.
The bike sits about an inch higher than my other gsxr but I think it looks right.

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Got the chain and sprockets here too, the chain caught on the top of the swinger so a massive thanks to WSR for fitting it in to take a little out of it. Pics will follow soon.
 
Well its been an eventful few weeks to say the least!

The bike got a little ride down the road but it was very lumpy and didn't want to rev at all. As well as that, it was really difficult to start and eventually didn't start at all as it was losing rpm signal when cranking.

Initially I found a loose ground and found that it didn't really like the 36-1 trigger wheel. With the ground sorted and the 36-1 wheel reduced to a 12-1 wheel it still lost rpm signal when cranking. The wheel would work fine from a drill at all speeds but never on the engine.

I've resorted to buying an oscilloscope (learning how to use it) and recorded the trace of the wheel/VR sensor and found that after looking for interference problems from the starter and/or wiring it isn't anything like that at all!
This is the trace.



Now I have to thank Chris from Trigger Wheels for his help and advice so far, I was lost ages ago!

The trace shows the signal is being affected by the engine speeding and slowing during cranking, (as mattturbocar said in my oss thread) apparently the ECU could have problems picking this up cleanly as there is such a difference in the peak heights and it could well group all the high peaks together and the low peaks together. That would explain why I didn't have any issues picking up and rpm signal with no plugs in!

So a 24-1 wheel will be made and this should hopefully sort my problem out.
Fingers crossed!
 
Well its been a rocky month with the bike, had various ECU issues which all turned out to be corrupt or the wrong firmware had been loaded before it was sent out to me.

So with that finally fixed the bike ran much nicer, I had a good lambda reading and the auto tune function was working nicely.
Then it suddenly started to make a very horrible rattle!

Killed it straight away and set about investigating the cause. Took the tank off and the plugs out, all good and straight, took the cam cover off and the valve caps had all returned and looked ok. Spun it over and could hear a faint knock but hard to locate it but it sounded more bottom end now so the engine came out!

Took the clutch out and some of the fibres have fallen off which isn't great but I didn't think too much of it, turned the engine over and removed the bottom case, all crank bearings look good, a little worn but nothing major. Big end caps came off next and all of those were good too.

Starting to wonder if I'd dreamt it now!
Turned the motor back over and pulled the cams out, first valve cap to came off had a loose shim and a collet wedged sideways where the shim should be!

Head came off to reveal valve and piston love making had taken place!



Now I knew this engine had dropped a valve before and it was purely to see if my set up worked so its no massive loss but it is a bit disappointing as it was so nearly road worthy.

After much discussion I think the original reason for it dropping the first valve was the clutch fibres in the oil, that crap is everywhere in the engine. Then the valve has been sorted but not the clutch, the valve cap is a little loose in the bore so I'm guessing its the same valve gone again.

Scrap head, scrap pistons and scrap barrels.

What can you do, sometimes you don't get lucky :(
 
Not sure yet, if I source another complete engine its £100 in gaskets to fit the spacer plate under the barrels. So easily looking at £400-£500 for that option.

Next option is to build the engine that I want, balanced crank, rods and pistons, new shells and bearings throughout, got a nice gearbox to go in, carrillo con rods, oversized low comp pistons for some good boost etc etc.

The £400-£500 would go nicely towards the engine rebuild and its not like there's a lot of summer left to ride it anyway.

Tough one.
 
This valve I think is the same one that went before, so a damaged guide or worn cap is a likely cause. Only needs to stick slightly or return a little slow and its in the way of a piston.

Think the first time it dropped a valve could be put down to the clutch fibres, only needs a bit to get by the valve caps to make it stick or wear the cap, its like grinding paste.


Just turned down an engine, will have a sort out and sort a few things out then start going through my engine bits a pick the best of everything, then start spending money again!


Ooo, this came the other week


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Sadly arrived with a little dink on the edge of the cover so it went back for a little touch up on the mill. Got a lock-up clutch being made too.

:D
 
Ooo big update here!

Firstly, I have a new set of pistons here ready for the new motor, forged and slightly lower compression but with a spacer plate it'll put it at about 8.5:1

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Comparison with the standard piston

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A set of KPMI valves, standard size.

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And as I got bored and seen these on another bike, I went and bought some new wheels!
Seen these ages ago and liked the look but never really hit the buy button until the other week.

All from a 2009 Buell 1125r










Been having a mock up tonight and thankfully, my spindles are smaller than the Buells!
The front will go in with some different bearings, a few spacers and some clever cnc bracket for the caliper I'd imagine.

The rear needs a little more, can't get bearings to suit the wheel and spindle so some top hat spacers to centre the wheel up and fit the bearings, not sure on brake caliper mounting yet and I need to come up with a way to cush, and inset the rear sprocket. Think I've got it but we'll see how it pans out.

:D
 
You should do a running total cost every time you update. :D Any idea what you've spent so far?

Nice stuff, very envious!

No idea what it's cost so far. I did start keeping receipts but I only have a few for the bigger bits.
Could easily make £5k I think without things like the stainless bolts, clips, all the smaller orders for wiring parts etc. Plus all the things that I've ordered that haven't quite fitted as planned and all the bits I've changed as the build has progressed.

Thing is, the more I do and learn, the better the build looks and then the first bits I've done don't look so good anymore!

These wheels are the final big items I'll be swapping I think, I'm happy with the rest of it. Just bodywork that I still haven't decided what to do with yet!

The master cylinders have changed too actually, got a K7 radial brake master and need to find a matching clutch sometime.

:p


Does anyone know where I can find the Buell disc mounts? Found them in Europe but at a cost of 125 Euro!
 
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Not much to update really, last couple of months has been tight on cash for one reason or another.

My head, barrels and pistons have gone to the mighty Roger Upperton, he'll be porting the head, re-cutting the valve seats and skimming it too.
Also the pistons will get a looking over, a small radius will be put on the top edge, valve cut outs trimmed a bit to prevent any hot spots, and if there's enough material he'll machine a small dish in them as well.
Plus a re-bore and the rings gapped.

I've been measuring the crank and rods up for the new bearings, just got to work out which bearings I need now.

Also got a set of cases completely stripped down, got to finish cleaning them then paint them up. Got some PJ1 satin black so just need to get the etch primer.

I've also bought zinc plating kit so just getting to grips with that, don't think they'll be much on this bike that I'll do but the GSXR and the DR have quite a few bits between then.

Actually sounds like quite a bit!

:)
 
Got my engine bits back from the mighty Roger Upperton the other day, very nice to see things coming back together.












Also, if you're at Event City this weekend keep an eye out, the bike will be there. Only empty engine cases but the rest should be in place.
 
The bike has made its first appearance in public, got quite a bit of interest actually which was nice.



I bought some koso clocks for it as well so I have the dash to alter now!
 
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