KZScott
Needs a life
high on speed
Posts: 7235
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posted October 10, 2011 10:07 AM
good news, bad news. dyno day
bad first. lifted the hg when pushing the upper limits of hp. good news is its an "easy" fix. I guess 27 psi of boost was too much but the pull at 25 was pretty sweet. it spit some coolant out the exhaust on the 27psi pull.
my 12 has a Master Power T3/T4 T60-1 turbo, home fabbed header, WA cooler built into the frame, AEM progressive water meth injection modified with Devils own nozzels plumbed into the TBs using some of my old nitrous stuff. It runs on 91 octane pump gas. MS2 ECU with upgraded firmware. 255lph Walbro external fp, AEM 1:1 regulator, ID 725cc injectors. I did all the work myself except for the tig. its been a real learning curve!
motor is stock bore and stroke, JE turbo pistons, and a ported head/modified combustion chambers by me. final CR ended up being 8.7:1. two stock intake cams, APE adjustable sprockets. APE studs, stock 01 crank and rods, 02 cases with oiling mods to restrict oil to trans(by me), R&D trans w/billet Robinson 1-4 output gears. Muzzy clutch basket, MTC lockup. I had 6 hd Muzzy springs in it and took my voodoo hold back springs off of the lock up to i had 4 arms applying pressure to make sure it didnt drive thru the clutch on the dyno(may have been over kill). Muzzy dry sump oiling system, filter relocator ect.
I had to build an attachment to be able to use the dyno. (the real one from Mustang is about 3k$$) this was the first time it had ever been put into bike mode, and i believe it had a calibration error. the operator is going to look into it for future bike use. i was mainly worried about getting a safe tune up and wasnt set on hp numbers, but for those who care, i believe it was reading exactly double what it was really making. at 25 psi it was showing 834 hp, so half would be 417. add roughly 15% to convert Mustang to dynojet hp and its about 479 at the wheel. it may have more in it as it was in the low 11:1 range AFR wise.
so Im waiting for Schnitz to get back to me about another Cometic HG. Im open to suggestions on changing the setup. thinking copper and ss rings may be required to hold more than 25psi on a 12?
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01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
  
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KZScott
Needs a life
high on speed
Posts: 7235
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posted October 10, 2011 12:32 PM
ok, this build has happened over various locations, and i cant thank everyone enough thats helped privately on my secret project. you know who you are guys, DM, JG, WH, DS, CH, ppl on other forums and local.
not trying to rip anyone off, but Ive sort of nicknamed my build the ultra ghetto 12. based on what it reminds me of. Motorheads ghetto turbo kits and Richards RCC ultra turbo kits. this has definately been a budget build which is why its taken over a yr. I havent allways had the best equipment or places to work, but I make due with what I have, and then every now and then I splurge a little if my CCs are getting close to paid off 
everyone wants pics im sure, here goes
header flange/turbo flange 1/2 mild steel.
hanging the turbo off of dads bike (making a jig). this was when he swapped to my old Brocks system and timing was perfect, my bike was in my apt bedroom at the time(no joke) and i needed to be able to weld the jig together. not possible in my bedroom!
making the header 1.5in schedual 10 304SS pipe
this design is one i would change a little if copying, i cant get 1 of the header bolts in, but so far its been ok. i think because the flange is so thick.
I would cut and fit pieces, using a 4.5 in grinder and a dremmel, then run and get stuff tacked by my tig guy.
my work station, making the best of what i had 
the rest of the exh was easier. 16 gauge 304 and a tiwinder meg. it was important to me to have good ground clearance both going down the track and making the turn to the return lane. I tucked it in tight as best i could, then fitted the gate. got it for a steal on SH.org. its, big, its rusty, but it works and has been over 220 at bonneville.
charge pipe. 2 1/4 tubing
frame mods and cooler.
this next part took a lot of fab work, and if doing it again, i would make a few small changes. used a WA cooler from frozenboost.com. core size is similar to whats used in the older ultra kits. i basically used my blown up motor as a jig to hold the frame from twisting when it was cut up/ welded on. went thru several design ideas during the build process
this part felt just like i was cutting off my own hand(minus the obvious lack of physical pain)
yes Muzzy stacks
1/4 plate
the cover has 2 grooves dremmel'd into it, and i sealed it with permatex ultra black(think engine cases). its no oring seal, but it working. after yrs of cursing the tiny inspection covers i really wanted a big one. this was the time to get some room to work when installing velocity stacks.
scotts damper mount, boost proof and never have to stick hands up in the frame for the nuts ever again. 1/2 in square stock drilled, tapped, then the ends of the holes capped with weld, flipped over and welded in..
water meth, direct port. only real way i could see getting even distribution post cooler
the pump and tank are located where the top half of the gas tank used to be, i need to get current pics
this was a tight fit
filter and return. i just made an adapter plate and used the oem tank gasket. pump is located in the battery box
cut down my stock rad to clear the turbo. electric water pump
i used part of another stock rad as the heat exchanger for the WA cooler. 2 seperate cooling systems. the second water pump is beside my fuel pump
turbo oil feed. i did a coil to hopefully account for thermal expansion. i didnt think a hard line would work in a short run, but the coil is flexable. the fitting on the filter relocator was soldered full, then drilled out to .063. this is something i want to check out now that its been on the dyno. and had some heat. its 1/8ss line, same as i use in nitrous systems and my water meth setup.
gauges. so far the MS2 can run the tach, but the speedo isnt working. i also have the water temp working. i wasnt sure if i would have been able to get it going with my computer programming "skillz" so i got the autometer gauge just incase
missing tooth wheel( cut one tooth off) so the ms2 can read crank pos without cam input. easiest way to get things running. batch fire the injectors and wasted spark
I plan on upgrading to full sequential with cam input at a later date.
oiling mods
pistons in the hole just a little. 2 base gaskets
from checking cr
modified chambers to lower cr. std size valves, std seats, stock IN, SS EX
running Carpenter 65lb springs, and APE Ti retainers
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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Shane661
Needs a life
Posts: 11494
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posted October 10, 2011 12:44 PM
Ultra-badass is an understatement!
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almost_les
Zone Head
Posts: 590
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posted October 10, 2011 01:03 PM
giggity
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KINGKWIK
Expert Class
9.36@ 149.23
Posts: 142
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posted October 10, 2011 01:22 PM
you bastard!!!.....I knew your were up to something....lol...congrats buddy...cannot wait to see that thing run! I assume your gonna ditch the shinko and go to a 7" slick.
____________
If it has wheels or tits its bound to be trouble!!
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KZScott
Needs a life
high on speed
Posts: 7235
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posted October 10, 2011 01:32 PM
thx guys. sticking with the hook up Lyndon. Ill try it anyway. if the local tracks cant hold this ill try the flat slick.
btw i ran an old hook up on the dyno(yr old) no issues, a tiny bit of spin but nothing major. had 6 straps on the bike. im told a sticky tire robs hp on a dyno? is it a significant amount or just a couple?
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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KZScott
Needs a life
high on speed
Posts: 7235
|
posted October 10, 2011 04:14 PM
heres a printout i was given, first clean pull on gate pressure (6lb spring turned out to be 5.3) and the pull at 25.3psi
keep in mind what i said earlier about the correction factor or calibration error...
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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Oz Booster
Expert Class
Posts: 230
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posted October 11, 2011 12:50 PM
Now thats a proper tubo system, congratulations
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KZScott
Needs a life
high on speed
Posts: 7235
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posted October 11, 2011 06:44 PM
ugh.... cracked the block. not sure if it may have had a factory defect or if thats just the limit....
who makes stock bore billet cylinders?
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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ZRXDean
Needs a job
Posts: 2225
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posted October 12, 2011 05:35 AM
Holy moly Scott! Incredible project.
I have a question - why run pump gas?
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KZScott
Needs a life
high on speed
Posts: 7235
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posted October 12, 2011 02:11 PM
its a "street" bike
just something i wanted to do. big power and "cheap to run". it would have been a lot easier to run c16 and not use the cooler or water meth, but thats just not what i wanted. theres a lot of debate here on what makes a car or bike streetable, pump gas is one of the top points
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted October 12, 2011 04:18 PM
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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Michaels12
Novice Class
Posts: 43
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posted October 12, 2011 04:20 PM
oh shit! is that a crack or are my old eyes deceiving me?
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KZScott
Needs a life
high on speed
Posts: 7235
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posted October 12, 2011 06:42 PM
yes, it was the block, not the gasket
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted October 12, 2011 06:59 PM
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
Shane661
Needs a life
Posts: 11494
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posted October 13, 2011 03:01 AM
 Edited By: Shane661 on 13 Oct 2011 11:01
quote:
its a "street" bike
just something i wanted to do. big power and "cheap to run". it would have been a lot easier to run c16 and not use the cooler or water meth, but thats just not what i wanted. theres a lot of debate here on what makes a car or bike streetable, pump gas is one of the top points
Do you guys have pump E85 up there? I thought about running it in my big 14 on the street, just not sure if it would be ok with the compression.
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ZRXDean
Needs a job
Posts: 2225
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posted October 13, 2011 06:58 AM
Just a little everyday maintenance on your 27psi streetbike
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KZScott
Needs a life
high on speed
Posts: 7235
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posted October 13, 2011 01:28 PM
no e85, or i would be running it. best i can get is 91 octane
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted October 16, 2011 01:41 PM
this week was sort of a mad thrash for me, im pretty sick with a cold and running on no sleep as usual. it was the last race of the yr and i really wanted to try the bike. i had a worn out stock block i used and managed to get the bike to the track sat afternoon. i hope the pistons didnt rock in the bores too bad and tag the head.... taking it apart in a few weeks after i catch up on some sleep/chores. i ran it on low boost this wknd and it felt really strong. its quite a learning curve to get the launch control figured out on the ecu, build boost on the line ect ect. i set the clutch pretty stiff initially and it bogged pretty hard, i upped the power in baby steps and my best today was a 1.53 60. any more power and it was blowing the tire off and going 45degrees sideways, into the other groove and allmost out before i got it under control. the pass with the 1.53 was an 8.86 @168.9mph. power was smooth and controlled after the launch. i really like the gear based stages of boost.
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted October 16, 2011 04:54 PM
a friend got a few pics
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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