Project; Turbo GSXR Slingshot

Few more bits done today, turned down the rear wheel spacer so it now holds the rear caliper bracket. Thats been bead blasted and anodised since the last pic.



And what it looks like fitted. Need a couple of helicoils yet but its there.



This was also made a while ago but I've never finished it as it needs welding and I didn't have a Tig.

This little piece and a self aligning bearing



Fits here to support the other side of the turbo.
Once its welded I'll push the bearing fully home and make a stainless pin to hold it.
Should let the turbo expand and contract whilst still supporting the weight.

 
Finally got round to ordering the head gasket, arrived today.



Took one last look at those pistons, hopefully won't be seeing them for a good while!

 
Got the cams in and timed up, cover is on and it's ready to go in the frame.



I'd stripped the frame down during the week and welded the turbo mount on, I've also built the lock stops up as they'd been cut down previously.
I've also altered the ecu tray, cut a bit more out to make it easier to get in there and plug things in and mount the subframe. Also cut a couple of holes in the subframe mounts.

I dropped the engine on its side and lay the frame over the top, easy way to do it on my own. It's on the abba stand now but no pics of that.

 
Not a W frame, it's an oil cooled frame with a water cooled motor. W frame would've been easier but that's not the way it went.

Didn't get much time on it yesterday.





Need the plenum back from WSR now.
 
So the newly o-ringed plenum arrived back from WSR, much better than relying on sealant.



Coming together nicely now, got a v-band on the exhaust instead of the flange that was there before.

 
Kinda had a little hickup with the cam timing. I checked it properly and the exhaust cam wasn't far off vut the intake was. As the timing was so far out I checked another cam to find it had a smaller profile. I thought I'd fitted a bigger intake cam that wouldn't be so good with the turbo.

Swapped it out for the smaller but had valve clearances like .5mm and .6mm!

In the end I've put the original cams back in and dialed them in to the correct lobe centres and just ignored the markings.

Didn't expect to be seeing these out


Put a couple or beads on the coolant tee, will stop it sliding past the jubilee clips


More parts in for good


 
Waiting on a few big bits really and I don't have much free time lately. Still coming along though.

Got some CBR pillion pegs but they didn't fit so altered them a little and put some spacers in the subby so it all tightens up.




Would you fancy sitting there? I wouldn't!!



I need to sort out a cable or something to unlock the pillion seat, not sure what yet but I'll think it over for a few weeks.

Will try and get some oil and a filter next week so I can get closer to firing it up again.
 
Haha, the girlfriend is a speed freak and loves going out on the bike so obviously wants a go on this.
Going to be grateful of that extended swinger!
 
Got the oil feed to the turbo sorted.
Tapped into the main oil gallery, I've welded the banjo up and drilled a 1mm hole in it. Flows about 1 litre a minute when tested on the other gsxr.

The check valve and fittings are a bit bulky but it works and it tucked out the way.



Also been working on the air shifter, bit of tidying up to do and need some grub screws but I think it looks tidy.





Also got some oil in it and turned it over a few times to prime some oil around the engine.
Getting closer to firing up!
 
Its going ok really, bottom yoke is finally in the final design stages so should get on the mill soon, cush hub is after that then top yoke.

Got the rest of the loom in, the ecu powered up and talking to the laptop.



Reads all the sensors ok and shows rpm when its cranking so its looking good.

Need to get some antifreeze, charge the battery, get some fuel in the tank and see if it runs.
 
It was a relief when it ran thats for sure!
Still a long way off running right but thats a job for someone who knows more than me and has the experience of tuning these things.

Got a Buell front end and rear wheel going in. Thats really all thats holding me up now.

Engine wise, everyting has been spec'd for 300bhp or more. Not going to get that much power but the headroom is there and it should hopefully be reliable.
I'll be happy with over 200bhp but 250+ would be nice.

Main thing is it has to be ridable and useable power.
 
Snaggle said:
other than looking trick im not sure making the braking worse would be the first thing i did when adding a turbo !! . theirs lots of talk about the rim brake but even buell themselves used twin discs on there race bikes
Click to expand...

I doubt any manufacturer uses standard brakes on their race bikes, just they don't have the option to add an extra disc.

Obviously it depends who you talk to and what you read but the worst I've heard about them is that they're no better than a good duel disc setup.

The benefit however comes from the bigger surface area of the disc keeping it cooler and the ability to be able to use a much lighter wheel , these give less rotating and unsprung mass so makes it easier to stop.

I certainly don't think its going to be any worse than a conventional twin disc setup.
 
So I've been having wheel to rad clearance issues again, it was close with the 750 front end in and the bike sat a little high. The Buell forks are 30mm shorter though so it would've meant having the bike sit high, the front wheel coming close to the rad under heavy braking and a big step on the top yoke to meet the forks.

With all that I decided to sort it properly and cut the rad down. The bike sits at the right height and I'll have enough clearance between the rad and front wheel.





That's actually the second attempt at welding the bottom up, the cross sections are .5mm thick so a slight jump on the arc or a little slip with the tig torch puts a pin hole in it!

Could be neater welds I think but I'm not exactly a pro welder...
Yes its a rough rad but if it works I'll look out for a decent one to alter.


Got the boost gauge mounted too, cut the mount off the old bracket with the gsxr clocks, tidied it up and welded a nut on the light frame.
Nice and easy.

 
So the rad is finished, leak tested and new mounts made on the bottom. Will probably make a better one once I know it'll work ok. No pics yet.

Also mounted the speed sensor, that was actually nice and easy.






Aquired a lathe off my dad the other week as well, nice freebie as he was upgradig.

Got the throttle body on there to open up the back so its round and matches the turbo intake.



 
Things are still moving slowly, I have a date with WSR to fit the lock up clutch and he'll also take it to the dyno for setting up the efi while I'm on holiday! :p

For now though, clip ons arrived but didn't fit, had to cut and weld some bars up on an angle to get them to clear the fairings, need to sort something better out really but it'll get it rolling. Also need a matching clutch master cylinder.



Clutch plates have had a nice oil bath and are fitted.



Bit of a rush to get the cush hub and top yoke made now, cush hub should be test fitted early next week, part one is made with part two on the mill.





Will then be anodised before fitting.
Bit hard to describe how the cush will work but it'll be clearer once both bits are made.

Top yoke is still in the design stages but I'm hoping it'll be ready in the next week or so. Fingers crossed.
 
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