Project; Turbo GSXR Slingshot

Fido McNasty said:
What a thing! :eek: :)
Click to expand...

Should be when its finished!

Picked up a Buell 1125 front end today, the forks look a little shorter but I'll have a look tomorrow and see how they're going to fit in. Got a fibreglass muddy with those as well but its not ready yet. He'll also probably help me alter my seat unit when the pillion seat goes on.



Dropped the crank, rods and pistons off for balancing too, should be back in a week or 2.
 
Had a quick look at the front end, custom yokes are on the cards.

Started stripping the engine cases ready for painting, Nitro Mors for the win!
Cruddy pic though!



Got the starter clutch cover primered so I'll give the a coat of PJ1 tomorrow and see what finish I get.
 
That'd be great if you could. The stuff I used was about 4 years old and I'm sure they've removed something from it now so its not the same anymore. I've got some double strength stuff coming but I don't know how good it'll be.
 
Cheers .one. seems tricky to buy though, need to find a local trade place that sells it.

I've cleaned the cases up with a bit of P600, came up good really.




Also started painting the odd bit, fairly easy really. Just have to build the black up slowly.

Cam cover primered,




And painted, dulls off to a nice satin finish when dry,




Starter Clutch cover



It shows up dinks etc but I'm not spending my entire life getting a mirror finish on an engine!

:p
 
The double strength Nitromors came today, does sod all now they've taken Dichloromethane out of it!

Just found some paint stripper pro though so bought 5L of that.
 
Got the pillion seat pretty much mounted, just need to find a lock. I wouldn't be getting on the back that's for sure!



Rear caliper hanger and torque arm came off the mill today, fits perfect first time. Don't know if I'm good at measuring and drawing or just lucky! Gave it a quick sand blast and got rid of the machining marks and it looks pretty trick. Will get it anodised black.

 
It was around £420 for the barrels boring, rings gapped, valve seats re-cut, porting, plenum matched to the intakes, cam sprockets slotted and delivery back to me.
Really good price I think.

The crank, rods and pistons have been back a few weeks now, that was £60 for all those balanced.
 
Well I did get the hanger wrong, thought it went too well!

Its now got a little recess to clear the pad when its in...




The cases are looking good too

 
Oh you'll know when its running! Was really wanting it on the road this year but as usual its down to cash, still silly amount to go on the engine.
Might get a few days at Santa Pod and a track day or 2 this year.

The rest is slowly coming together though.
 
Started to measure the crank bearings up last night, got the big ends done and should have the main bearings by the end of the week.

The big ends measure up at 0.042mm 0.046m 0.046mm and 0.048mm clearance so just about perfect.




 
£400 is a lot yea. Shims aren't too bad but they are time consuming and fiddly when the engine is in the bike. I guess that's why you've been quoted so much.

When I had the head off the other gsxr rebuilt it cost £360 for re-cutting the valves, shimming, skimming and cleaning all ready to drop back on.
 
Just placed an order with Robinsons for the main bearings, plus a few seals, O-rings etc etc....
The valve stem seals were on offer as were the spring seats so I bought those too, I'm living off beans on toast for the next month!
:p
 
Started to sort through some engine bits to find the best ones, cleaned a few bits up and placed them in. Found dowels, sorted crank bolts out etc!
Got the gear shift about figured out now, seemed obvious when I took it apart, thankfully I have a manual.

I've stupidly put half of my good gear box in the mock engine which I bolted in the frame for the manc bike show so I need to strip it all out to get it!
I'll do some measuring up for my air box etc first though, while its in one piece.



Been told from Robinsons one of my crank bearings has been ordered from Japan so it's a 2-3 wait for that.
Got a few more bits on the way including a base gasket so I should hopefully be able to work out the comp ratio and see how much my pistons need altering.

The bottom yoke is also drawn up ready, just needs a few hours of machine time and I may have a front end starting to go in.
 
The Robinsons order came through last week, checked it over tonight and I'm not best pleased. The main crank shells are nearly all scrap.

I have 4 halves in bags with part numbers written on by hand.
One is either the wrong part or the wrong part number has been written on.
I have a shell that's black and looks corroded.
These don't appear to have the colour on either so other than a hand written number I have no way of knowing its size for sure.

I have 8 boxed halves, one looks good but all the rest have the plating missing/peeling off the back.

Very disappointed with Robinsons to be honest, I don't expect them to inspect boxed shells but sending shells out in bags is bad, especially when they're clearly useless.
Its not like they're cheap either.



 
They said to send back the ones I'm not happy with and they'll replace them. I'll send all the shells back and I think its fair to only accept one in the original box.
 
Finally I have some shells! Took long enough. ..

I've moved house since the last update so I've been busy sorting the garage and shed out ready for some bikes!

I do like having my own tidy work space!

Started fitting a few bits into the lower case, oiled the oil pump up and fitted with new O-rings, got the selector drum and shift forks in too.

Ready to plastigauge the main shells tomorrow aftrrnoon.


All genuine Suzuki O-rings, circlips, shims etc.




The long awaited shells!




Dug the crank out ready, all nicely balanced.

 
Been a while, not too much has happened but I'm still making progress!

The shells gauged up fine, one slightly over .05mm one slightly under .05mm and the rest crack on .05mm

Held up now as I need 3 more gearbox bearings to get the bottom halves together and they come in at £180!

Got the halves together and the barrels on so I can cc the pistons and measure the piston to deck height.



Worked out the comp ratio, I cc'd No.1 chamber on the head and a piston in No.1 cylinder set 1mm down the bore.

Combustion chamber held 24.4 ml so 24.4cc

Piston 1mm down held 6.5ml so 6.5cc

77mm bore 1mm deep is 4.66cc

6.5cc minus 4.66cc = 1.84cc which is my piston volume.

Piston deck height is 0.533mm

Cometic do gaskets in multiple thicknesses so I've worked it out with 2 different ones. A 0.018" and 0.040"

So with all that, it came out at
9.38:1 with the .040" gasket
10.05:1 with the .018" gasket

The .018 gasket gave me a squish band of 0.96mm and after input off OSS it was suggested that this may be too tight for a boosted engine.
So to get my comp ratio right with a bigger squish band I'll use a .027 head gasket and have a dish volume of 1.96cc, it'll work out at 9.24:1 ratio with just over 1.2mm squish band.

The dish volume is equal to a pocket 1mm deep by 50mm diameter which with removed material and tapered edges it should work out nicely.

The pistons were sent to Roger Upperton last week for a 2cc dish to be put in them.


Stripped to head and cleaned it ready for primer and paint.



2 coats of primer and a fair few thin coats of PJ1 and I have this.




New set of valve springs, gear shift springs and an oil gallery plug arrived today.



May get the valves in tonight then the tedious task of setting the clearances!

:)
 
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