super awesome turbo now in bits again

[Nobby the Bastard]

A slight semi? I'm wanking like a good-un....
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[CHR15]

i was thinking about rider controls this evening.

i want everything to be usable with my hands on the bars but traditional switchgear doesnt have the right kind of controls i need.

i noticed suzukis new motogp bike has some sexy things;

https://blogs.c.yimg.jp/res/blog-e4-53/suomybbbb/folder/1583792/24/54106824/img_2?1372223726

hunted round and managed to find the buttons they use, did a little sketch;

https://i939.photobucket.com/albums/ad233/chris-bracey/1_zpsf3f051c9.jpg

might knock a pair out after work tomorrow.
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Pete.]

Integrate it into a throttle cable housing for extra cool-points
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[bladerunner]

So long as you stop the wires rubbing on the throttle cable!
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Current bikes...cbr929, KDX200's, Rd125lc mk2, RGV250's

[Souleh]

There are switches like that readily available but quite dear

[Irn-Bru]

What do all them buttons do? Take it the red one is the kill switch? I like buttons.
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KTM 990 SMT & Suzuki DR-Z 400 SM

[CHR15]

i dunno. they'll do something useful though.


just need to clamp the halves together and machine the clipon hole.

https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/p180x540/10171176_10152005528833365_961436755_n.jpg

https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/p180x540/10153242_10152005528883365_497700300_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/p180x540/1975210_10152005528963365_1441450055_n.jpg
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[lllN30lll]

[CHR15]

wow.


those buttons are £5.71 each from rs.

that thing took me under an hour to program and machine.

if i was making another one it would take me under half an hour to do as a one off.

if i was knocking them out in batches it would be about 13 minutes each.


they must be making like 57000% markup.
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[lllN30lll]

If you decide to make more, I'll be interested, and I can sell them on my S1000rr forum for you. But yeh, that's how much we have to pay for the race switches, there's no cheaper alternative.
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Turbo R1
CRF450R

[CHR15]

bmw's run 22mm bars?
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[lllN30lll]

Not sure, that advert mentions replacing the whole throttle housing for some reason. I'll try find out.
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Turbo R1
CRF450R

[CHR15]

can she tig weld though.....


2+3 primaries done.

1+4 to start tomorrow. they'll probably take me a bit longer though.

spiggot things machined, lazered clamps and some tube.

https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/p180x540/1422441_10152041453008365_4375322839428599846_n.jpg


https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/t1.0-9/p180x540/10259898_10152041453023365_8974298712961389221_n.jpg



bit of cutting and welding...

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/p180x540/10171135_10152041453018365_1746622704174459494_n.jpg

https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/t1.0-9/p180x540/1458696_10152041452998365_1135512371956437140_n.jpg


looks like it sticks out a long way, but once its in the frame its actually pretty tight.
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[G]

On the switches...
Well, they do say you're supposed to use the throttle as a 'switch'.

I've oft' thought something like that would be useful for controlling phones with bluetooth or similar - you'd need software setup to use it, of course - but it'd be nice to have basic music, satnav and call controls at your finger tips.

[CHR15]

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/10271547_10152043720443365_6835251531174868261_n.jpg

random shot of the fit between the tube and the inside of the head spigot


https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t31.0-8/10271230_10152043720428365_8033424356175828232_o.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/t31.0-8/10293747_10152043720418365_3895651509512930982_o.jpg


just need to mitre 1+4 into 2+3 which is the epic difficult bit.


then cut the wastegate flap out the new turbo

https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/t31.0-8/10007377_10152043720438365_335992527270247123_o.jpg

bake at 200 degrees until golden brown,

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-frc3/t31.0-8/1909248_10152043720433365_3755614888006625097_o.jpg

then weld in a divider plate.

housing is back in the oven to cool down over night.

will skim it off tomorrow.
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Souleh]

[stevo as b4]

Chris, I'm forgetful and probably have asked this before sorry, But is the work you've done to remove the IWG due to:

1, An internal Gate just won't work on a bike motor for the kind of set up and use you have in mind?

2, Because you already have all the EWG and plumbing to fit, or that it gives you more clearance to mount the turbo etc?

lastly if one wants to disable an internal gate can it be done by welding the flap shut, or is this a big Fail?

On my car motor, there's currently a long threaded rod bolting to a steel bracket on the gearbox housing to keep the IWG shut, and it works, but the fussy person inside me says it's a bit of a shitty solution.

[CHR15]

option 2.

also the ewg ive got is 2 port so i can run a pwm controlled boost solenoid.

i used lockwire on the old ewg to keep it shut.



dont see any reason why you couldnt weld it up. as long as the gate penny is of a suitable material and you prep it properly.


1+4 welded in tonight

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc1/t31.0-8/r270/904526_10152047858753365_7012353970305585628_o.jpg


and skimmed the housing

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/t31.0-8/1511645_10152047858758365_2584983343596483667_o.jpg
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Pete.]

That collection point to bring all the four headers together is a beggar to cut isn't it? I put hours into getting mine right, and afterwards decided that if I ever did it again I would start with the collector and work my way back to the ports. Mine moved about all over the place when the collector was welded and it was whilst fixing that I found that it is actually very easy to shift and adjust things as you go. For instance, where you have the outlet below the four-way join it's binocular-shaped but it would be very easy to shape that to match the hole in your flange plate. How thick is the plate you're going to use by the way? Anything less than 12mm is very likely to dish badly when you weld it. Mine did and I had to spend probably an hour filing it flat again.

Nice welding there BTW Chris - you do all that yourself?
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[CHR15]

i know what you mean.

nibble a bit out, see if it fits, nibble a bit out, see if it fits.

flange is 10mm. the last one i did, i tacked it, got it proper hot with the bottles and then welded it. still went a bit but wasnt too bad. i can always set it up on the mill and just take a lick off.

yeah weldings all me. hands are too shaky to make it really good but its not too bad.
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Pete.]

Look good to me, but welding isn't my strong point (sic).

Autogenous or using filler? My first headers were autogenous welded and I had to have them gone-over with filler as I had bumped into a welding inspector who said they would fail. I was lucky as I had no idea there was trouble loomin'
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[CHR15]

autogenous on header spigots and pipe joints where the fit was perfect.

filler on the 4 merged pipes cos there was like .5/1mm gaps where the die grinder got a bit happy.


the last set were also autogenous, the only place i had failure was where i branched off for the wastegate, but i did have the weight of the wastegate hanging off the joint at 90 degrees. should have braced it really.


the turbo is going to be hung off the frame anyway with some little turnbuckle tie rods. probably with urethane bushes on the frame end otherwise i imagine it might crack from vibration.
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Pete.]

I'd think about relieving that wastegate hole Chris if I were you cos little turbos love to creep on bikes. If you do it by hand I'd suggest you ovalise it with well-rounded edges and take some off the inside top edge and outside bottom edge. I turned mine on my lathe - same housing as yours, but in hindsight I think hand-profiling would have been better. Still got the jig somewhere.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[CHR15]

wizz wizz and more shiny things appear.

https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn1/t31.0-8/10265310_10152057937483365_386190592059330915_o.jpg

https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/t31.0-8/10012278_10152057937488365_9047497178927595463_o.jpg

which bolts onto:

https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/t31.0-8/10295057_10152057949363365_2116567007645289598_o.jpg
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Howling Terror]

Nice bevels dude.
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Diabolical homemade music Bandcamp and Soundcloud
Singer songwriter, Artist and allround good bloke Listen to Andrew Susan Johnston here
The Harry Turner Project