whitehendrix
Zone Head
fails!
Posts: 757
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posted October 10, 2010 12:31 AM
 Edited By: whitehendrix on 10 Oct 2010 08:40
turbo build thread
i thought i may have done one before, but honestly i cannot recall. lol
this will be the official bikeland thread. i have a few others floating around on other boards..
first off, i want to thank Jim, Tim, Doug, Karl, Scott and everyone else for not only the "push" to chase records and the dream of running in LSR, but for al lthe technical help and sharing invaluable experience not only with me, but everyone else on here. alot of us woulda be pretty stuck if it weren't for your inputs, guys.
ok. after much number crunching, debate and thought and info reading, the basic goal is this ( with respect to what Ali told be a few months back about "easing into it" and not going for big numbers the first time out..)
the bike as it was just before my epic highside on aug. 23rd.
the bike will be a turbo'd 2000 ZX7R. stock displacement. stock bore/stroke. mild engine work. fully built custom header, intake, EFI conversion, various "things" to keep stuff in check.. HP goal is between 200-300 to the wheel (BHP)
the turbo on initial testing will be a T25-flanged Garrett TB22. .63 turbine A/R, .48 compressor A/R
the turbo that will find its way on the bike for the "final revision" will probably be whats called a "disco potato" ( what a great name, eh?)
the turbo is a Garrett GT2860RS. dual ball bearing.. very nice. EXACT same flanges and all as the TB22 i have now.
upon my math, i discovered the TB22 is too small and will not support anything over 200HP as per my airflow calulations.
i did airflow calcs once already.. but plugged in a VE that was not consistent with the port modifications i will make.. VERY mild, as per Dr. Meyer's input. basically following "keep it simple" instructions.
i have not settled on a CR yet.
the EFI system is also a design phase. it will utilize CBR 1000RR TBs, stock injectors. i may or may not retrofit a factory ecu from.. ONE of the big four to work.. doing so will require me to add a cam sensor and modify the trigger coil.
the other option is a megasquirt unit.. they also double as a datalogger.. so, that may be the best bet.
i will swap to 2000 ZX6R coil packs for individual cyl ignition control.
the headers i'm using at this time are modified CBR954 headers. unknown grade stainless. they will be pulsed TIG welded with 100% argon, 2% thoriated tungsten, 308 filler rod ( since thats all i have )
metal itself is about .050"
eventually i will build one with mandrel bends and possibly run a twin-scroll turbo, separating cylinders 1/4 from 2/3 to help alleviate some backpressure from exhaust pulse reflection.
had to remove .200" from the seal ring's end and .040" from the O.D to make them fit. they were free tho.. so i won't bitch too much.
i have plans on intercooling. i will make this work by building a carbon fiber or aluminum tray for this IC to sit on.. use ram-air air.. blow from bottom to top, and duct the hot air out under the tank remotely.. probably dump it near wher ethe battery is.
i have two orientation configurations.
either way will work. wither way i will be blasting off the end tanks with the plasma cutter and welding my own tanks up.. lol
OR
^ this one being if i cannot plumb the ic from the turbo directly for some reason.. i will go thru the ram-air port in the frame.
he modded cbr headers are about 20-25 degrees off of where i need the radius to actually be at.. i will cut and weld to get around this.
after an hour of so of measuring, experiments and whatnot, i figured this mounting height may be as good as its gonna get. close enough to keep the run short and exhaust gases hot, high enough to possibly, hopefully gravity feed into the pan without a scavenger pump ( for turbo oil return) but low enough to not warrant alot of mods to body and radiator position or whatever.
oh.. yes. the inside of that compressor IS shiny. i ported the fuck out of it, polished it to a perfect shine. haha.. trying to get as much efficiency out of every nook and cranny on this thing.
the motor that will actually go into the bike on a rainy weekend.. once i settle on a solid CR number, install a few parts and get my game plan locked in..
i think we all saw my venture into head modification.. i will hopefully fix the #4 seat where i arced to it 
and as of a week or so ago, when we were in the middle of getting 22" of fuckin rain over a 4 day stretch, i started chopping and welding stuff. only got as far as fusewelding the joints.. had no stainless filler wire.. i got stainless filler now tho 
heres a little practice i did setting my machine up. first time welding stainless with it. i have done aluminum and steel with it before. setting was done thru the foot pedal. 10% valley current on pulsed DC, 15CFH of 100% argon, 2% thoriated 3/32 tungsten. max peak anps set at 40.
so pretty.. lol
heres the start of #3 header. as it is.. not finished yet but will be very soon.
lastly.. since i forgot to add it earlier, the compressor map for the TB22.
supposed to flow 304CFM.
i sadly punched in only 90% VE to get an airflow rate at redline for my motor. found that 13.5psi was perfect to stay on the peak eff. island and still make good power.. but as i stupidly punched the wrong number in for VE, i now know the flowrate of the motor is high than the turbo can make (efficiently) again.. once i settle on what my VE actually should be ( trying to figure that out now) and when i am bored enough to do math, i will re-crunch the flowates. probably going to be around 400-440CFM or so.
i am waiting for a badass EE job on tuesday. if this comes to fruition, i will really start knocking this out fast. may even toss some nice parts to the thing.. Dr. Meyer said the rods are good to 500hp, but at the same time, i would love to see a set of carillo H beams in those bores *drool*.. and a set of kibblewhite Ti retainers up to to keep my factory pro adjustable cam gears company.
either way, this is my official build thread and i will keep it updated with the progress i make.
thanks for lookin and wasting your time so far!
more to come..
____________
Duct tape is the handyman's secret
weapon. The black is for formal
occasions. - ZRXDean
ill never own a busa unless
someone gives me one.... and then
ill sell it -KZScott
  
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whitehendrix
Zone Head
fails!
Posts: 757
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posted October 10, 2010 11:41 AM
you know what really fuckin sucks? these damn headers are titanium. NOT stainless.
got some SS 308 filler wire. was all happy thinkin i was going to start getting something accomplished.
add the wire to the puddle and i get this
totally sucks. back to square one now MAN that sucks. i put alot of work into making those things fit just right .
not i need to find a stainless header for the 7R.
total fail.
____________
Duct tape is the handyman's secret
weapon. The black is for formal
occasions. - ZRXDean
ill never own a busa unless
someone gives me one.... and then
ill sell it -KZScott
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KZScott
Needs a life
high on speed
Posts: 7235
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posted October 10, 2010 03:48 PM
would a stock header from a 12 do you any good? (free to a good home)
I would suggest thicker tubing tho.
____________
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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whitehendrix
Zone Head
fails!
Posts: 757
|
posted October 10, 2010 05:43 PM
well sir, ironically 2 fat 2 fly suggested a 12 header as well.
its sure worth a shot if you have one i can experiment with.. whether it's steel or stainless.
the Ti woulda been fun tho just to SAY i had a Ti turbo header.. lol sounds exotic.
the .050 walls did scare me a bit, but that is why you support and batton the thing like a champ.
give me a bit to see if i got this job so i can catch ya on the shipping costs?
____________
Duct tape is the handyman's secret
weapon. The black is for formal
occasions. - ZRXDean
ill never own a busa unless
someone gives me one.... and then
ill sell it -KZScott
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted October 10, 2010 07:00 PM
need any measurements?
____________
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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whitehendrix
Zone Head
fails!
Posts: 757
|
posted October 11, 2010 04:57 PM
well, the modded headers i have have the seal ring whittled down to 1.650" from an original 1.690". mighta even been 1.700"
i am more than willing to give em a try tho. worst case scenario is the primaries are too big, or i have to get to a lather and turn some seal rings.. or weld around the pipe and cut them out of the welded section..
____________
Duct tape is the handyman's secret
weapon. The black is for formal
occasions. - ZRXDean
ill never own a busa unless
someone gives me one.... and then
ill sell it -KZScott
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