My sportbike build- an update....

So I've discovered the inherent flaw in using pie cuts for everything. Besides tons of welding that is. All the heat from welding, and all the little gaps added together means a lot more opportunities for the metal to pull. I finally welded up the exhaust and the turbo manifold. The turbo mani pulled almost a quarter of an inch, so I had to cut it apart again and add in a section to get it back where it needed to be. Whew, that was a lot of welding







Also I welded up the fuel rail and installed it. I still need to figure out some mounting tabs for it, but it just looks so cool in there I had to take a few pictures!



It's a tight fit for sure.



I'm optimistically about a month and a half away from starting this thing up, got to start checking things off of the list so I can accomplish that.

Welding up the intercooler piping is next.

thanks for looking
Sky

Yamaha_chop said:

I'm going to run right around 12lbs of boost, and it will be intercooled. should give me about 88hp, so maybe 80 at the rear wheel which is still a substantial amount.

The turbo is a K04 turbo from an Audi TT. I can post the compressor map if you want. It's still a tad large for my application, but it's almost impossible to find a turbo that was used on a production vehicle that's small enough for a 650cc engine

And no problem on the questions too, I love to ramble about my projects

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I thought that turbo looked familiar... I am big into modding VW's and Audi's. You could easily swap out that that Ko4 for a Ko3 if it turns out to be too big for your application. the Ko3 is much more common (on almost every VW 1.8t engine) and there was even what they called a "baby" Ko3 that came on the first few years of the turbo Beetle that would probably be perfectly matched to a 650 engine. all the bolt patterns are the same and should swap easily, and if you decide you wan to try a baby Ko3 my buddy has one kicking around that he would probably sell for close to nothing.

good luck with the build, cant wait to see it finished!

Yamaha built a turbo Seca, as I recall, that was about 650cc or maybe 600cc in displacement. Dunno what sort of turbo they used, but I reckon it was fairly tiny. And I'll bet it wasn't running more than about 6 psi of boost or so. Seems to me that, with a turbo that's oversized for your application, it'll be a bit slow to spool up. You might can also do like other turbo-heads do and play around with a hybrid setup. Keep a larger compressor side, and look for a smaller turbine side, which will provide faster spool-ups while still retaining the same compressor maps.

One trick I picked up recently, that I did to my Volvo's Mitsubishi TD04H-13c, was to port and polish the turbine housing, especially around the wastegate port. This is done to reduce temperatures in there as well as to improve flow and reduce back pressure. It was easy to do with a die grinder and bits that'll work for cast iron. Followed up the porting with spiral sandpaper bits to smooth it out real purty.

Are you running stock pistons? Given that the stock XS650's motor has only about an 8.4:1 compression ratio, I think that, with a good EFI controller -- especially one that could somehow be tied into your electronic ignition setup -- you can safely do more than 12 psi. But 12 psi is a good starting point, methinks. Using Volvos as an example, their B230FT motor, which is the one they used for the 700 and 900-series turbocharged cars, has an 8.5:compression ratio, and you can safely run about 15 psi with those motors and not run into trouble. But then the EFI and ignition systems are tied together, so if ping is detected, timing is retarded almost instantly.

I know what you mean about the pie cuts. Made a full SRT-4 exhaust once from scratch pie cutting everything and designing a complete new y-pipe for the rear. Needless to say .. once, is cool. You get to step back and look at it and go wow .. thats sweet. You get that feeling of accomplishment .. then the immediate next things that go through your mind is "I did this job way to cheap" .. and "screw that i think ill just bend it up next time".

haha .. anyways looks nice man

That exhaust does look like it was quite a bit of work. Any reason you didn't cut a couple of pre-bent pieces and weld those together like you did for the side that comes off the turbo?

Dang that thing looks sweet!

Can't wait to see the next update! I have just started my first XS build to be a chop. I know exactly what I want to do when that one is done!!

Travis said:

That exhaust does look like it was quite a bit of work. Any reason you didn't cut a couple of pre-bent pieces and weld those together like you did for the side that comes off the turbo?

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second that

Do you have any concerns about having the turbo that close to the fuel rail & the plastic injectors?

Awesome build mate.
Im getting bits together to turbo and EFI my XS650. Im using a turbo from a smart car. (probably twins in twins in the end) originally from a 700cc diesel, only boosts to about 7psi though





Im concerned obout oil flow to the turbo though especially since these arent ball bearing turbos so they will require more flow.
What are your plans? Im concerned just tapping in to the existing head feed line may rob too much pressure
I was possibly considering mounting a second oil pump in place of the starter motor

That's a sweet little turbo man!

You'll see what I did for oiling in this update:

Betcha thought I was dead right?

Haha, man been working a lot on this thing lately, about time to get back to the fabrication side of things, but here's a video to show you what I've been up to!

YouTube - Turbocharged/fuel injected XS650 It runs!

Man, it's been amazing to actually get the engine to start up, it's validation of everything I've done so far. It really gives me the motivation I need to really get back at this thing and get it going. Now that I know I'm not just wasting my time with it I can really put forth some solid effort.

Two things: The sound quality is pretty bad on the video, sorry about that. It sounds better in person. It also sounds like it's idling at 4000 rpm in the vid, in actuality it's somewhere around 1700rpm. Also I was kind of bummed because I figured that with the two into one exhaust and the turbo it'd sound pretty different. Wrong it sounds identical to my chopper! Hah, guess I should have seen that one coming since they're the same engine, but still, maybe it'll sound different once I get it under load and really up into the powerband.

Thanks to everyone who's been writing and asking about this. It's been a labor of love and even though it won't be rideable for some time yet, I really appreciate everyone who gives me feedback on it.

Hope you enjoy the video and if you have any questions at all feel free to ask....
Sky

Wow, very cool! Sounds wicked

I really dig this project and get psyched every time I see an update. It just gets better and better, brother! Thanks for the share.

Truly innovative and most excellent. This bike will be wicked. Did you upgrade your charging system? You'll need a reliable one for your EFI for sure. I also am wondering about your turbo oil return. Do you think you could go straight down into the case instead of to the side cover? Maybe I should inject my GS!

Great work! Keep the updates coming!

I love a rat's nest of experimental wiring with sensors and controllers and actuators. Doesn't matter what it is, motorcycle, atom smasher, doesn't matter

TRULY INSANE!!!!!!!!!!! That's why I like it!!!!

xjwmx said:

I love a rat's nest of experimental wiring with sensors and controllers and actuators. Doesn't matter what it is, motorcycle, atom smasher, doesn't matter

Click to expand...

I haven't wired it in yet, but I'm also going to be running electronic boost control. And I just recently have been reading about another sensor that through pulse-width modulation of the fuel pump can keep your fuel pressure in check instead of using a mechanical regulator, which would clean up the bike a lot.

The throttle body I'm using has a spot for an IAC valve as well, I currently have it blocked off, but I've been thinking about getting that wired up as well.

Thanks for the continued interest guys, I hope to keep the updates coming.

A friend and i ran one of the early versions of MS on a 1g awd dsm (eagle talon) about 5 years ago.. it was really awesome the first time it fired with the new sensors the circuit board and the rediculous tune we had on it.. the feeling is awesome.

Looks cool .. wideband ms tuning is awesome. Just incase you hadnt gotten any info on them before the factory mitsubishi injectors for turbo DSM's 90-99 were 450cc's (42lb) and the JDM injectors for the early models had a 510cc (48lb) option. I think i may have a set of four of each. If you're ever interested in them let me know..they should be the same size, mitsu made a lot of the equipment for the srt4's and most of their DSM stuff even now becoming 20 years old .. is still quite bullet proof.

Good luck .. looking good.

Luke

was it building boost at idle?? I thought the gauge said 20lbs!!! but i couldn't se it well...??