ADVrider

Go Back   ADVrider > Bikes > Some Assembly Required
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 02-09-2011, 07:45 PM   #61
omnivore
SuperSportTourer
 
omnivore's Avatar
 
Joined: Jun 2004
Location: Brantford,ONT,CAnada
Oddometer: 1,013
Quote:
Originally Posted by Tommy_J View Post
Very nice idea. That looked like a big assed turbo. I'd have to start with a little soup pan.

.

Stainless dog dish from pet store or Dollar General
__________________
XR200R
KTM 950SM
CBR Fireblade-GTU Endurance racebike
1996 YZF 600-Lost Era racebike
1999 R6-Rookie Challenge racebike
omnivore is offline   Reply With Quote
Old 02-09-2011, 07:55 PM   #62
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
It turns out there was no need to have cut this clearance hole in the bodywork. Tonight I'll try to make the best of things and make a panel to fill it in. I may use the panel to mount a tiny boost controller valve.

.
Attached Images
 
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +

Tommy_J screwed with this post 02-09-2011 at 08:33 PM
Tommy_J is offline   Reply With Quote
Old 02-09-2011, 08:53 PM   #63
snowhawk jockey
Slack Jaw Gaper
 
snowhawk jockey's Avatar
 
Joined: Jul 2005
Location: The other Center of the Universe: Bend, Oregon
Oddometer: 1,130
Sorry to see your preemptive strike has hit an empty bunker! Will the panel repair be in steel and have nice rivets around the perimeter? It could turn into one of the "telltale" trim pieces with the little boost knob hanging off it. The controller could be readily accessible and yet recessed enough not to hang up on your gear as you slide from the gas cap to the tail rack, when the boost hits.

edit to add:
If my side panels were shiny, I'd offer to trade. Mine has grown a raspberry or two whilst sliding a bit too sideways on the cinder roads...

snowhawk jockey screwed with this post 02-09-2011 at 08:59 PM
snowhawk jockey is offline   Reply With Quote
Old 02-09-2011, 09:11 PM   #64
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
I'd hoped the cheap little ebay boost controller was little enough but on second thought it would stick up a bit too much to mount there.

Sooo, I'll put in a screen for ventilation. I can't say if this ventilation will be good or bad but at least the panel doesn't look like a mistake anymore.

Card board pattern and 0.1" aluminum screen




Trimming in progress


Fin.
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-09-2011, 10:13 PM   #65
snowhawk jockey
Slack Jaw Gaper
 
snowhawk jockey's Avatar
 
Joined: Jul 2005
Location: The other Center of the Universe: Bend, Oregon
Oddometer: 1,130
Nice grill!! I hope you don't end up roasting any weenies on it...

So, that is such a cool piece of trim, I, the no bling king, need one!
(scratches are my idea of bling for the Orange beast)

This means I have to get my ass out into the shop and get to work. Should take only a week or so to get the bench cleaned off. I have been neglecting too many projects, of late, and there is a huge pile of shi* where my bench should be.
snowhawk jockey is offline   Reply With Quote
Old 02-10-2011, 08:23 AM   #66
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
A box of J bends from ebay. 303 stainless with 1.5 inch diameter. This diameter looks small compared to the stock 1.75" but is probably the best size for a turbo. One of these bends was special. It has a tight radius 90 bend that will be used at the connection to the turbo.

$120 delivered and is enough for the next project too.

.
Attached Images
 
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-10-2011, 04:10 PM   #67
Quedok
Gnarly Adventurer
 
Joined: Sep 2006
Location: Long Beach, Ca.
Oddometer: 190
Welding 303 stainless

I hope that is is a misprint and the material you have chosen is NOT 303. Let's hope it's 304. The problem with 303 is that it is a free machining stainless steel. It has sulpher in it's composition and that is not good when it comes to welding
I have done it before but it is not recomended. It can be done by using low heat and adding filler rod right away to prevent cracking. Use 308L filler rod. Again it's probably a misprint.
Looks like a fun project so far.
Quedok is offline   Reply With Quote
Old 02-10-2011, 09:04 PM   #68
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
I assumed it was 303 based on the price. The ebay auction actually didn't specify the alloy. It seems to weld very well with a TIG machine.
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-10-2011, 09:41 PM   #69
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
A bit more stitching on the muffler. Baffle assembly is in. Then the end plate that attaches to the turbo can get tacked on. At that point I can bolt it up to the turbo and mount it to the bike. Then, finally, header construction can begin.

.









__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-10-2011, 10:41 PM   #70
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
About the headers -

It would be so easy to make a 12 inch pipe to connect the factory header outlet to the turbo, but that's not what I plan to do.

In the very first post I said an objective was to improve off road ability. One way to make this happen is to loose the exhaust pipes under the engine. I bashed mine in when the bike was a week old. To solve the lack of ground clearance a whole new exhaust will be made from scratch.

Here's my well bashed header. KTM was moronic when they gave this bike more suspension travel than ground clearance. Any jump at all could ground the stock header.
.
Attached Images
 
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-11-2011, 06:57 PM   #71
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
A snap decision was made not to use the the stainless tubing bought just for this project. The original plan was to make new 1.5" fittings and flanges for the cylinder head junction. To do that means no real progress over the weekend.

Instead I'm going to scrounge 1.75" stainless from the stock header and 4 Ducati mufflers that were laying around. Hopefully this is enough tubing. I better not screw up.

.
Attached Images
 
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-11-2011, 10:30 PM   #72
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
This is the tubing available to build a new header out of. Should be just enough. It feels kinda scary to cut up my stock header. No going back now!

.
Attached Images
 
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +

Tommy_J screwed with this post 02-11-2011 at 10:36 PM
Tommy_J is offline   Reply With Quote
Old 02-11-2011, 11:13 PM   #73
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
The EX-KTM header.

.
Attached Images
 
__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-12-2011, 10:14 AM   #74
Tommy_J OP
won't drive a car
 
Tommy_J's Avatar
 
Joined: Apr 2007
Location: So Cal
Oddometer: 338
Assembly of the new header begins by installing a piece of the stock header to the head. Bits of the old header are trimmed to follow the desired path.



Chunks of the old pipe were cut to appropriate length and the joints mocked up by taping together. This routing is similar to the SuperEnduro's.



Once I'm sure the layout is what I wanted I took the pipe off. A bit of the tape is pealed back so a tiny tack weld cane be made.



Just two tacks per joint will be used at first. As things progress more tacks will be added.



Pipe back on for a test fit.

__________________
Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250

Past stable : 90 +
Tommy_J is offline   Reply With Quote
Old 02-12-2011, 10:21 AM   #75
Maineroads
Ridgerunner
 
Maineroads's Avatar
 
Joined: Jun 2007
Location: Peak of the Valley, Maine
Oddometer: 831
What do you do for a living Tommy?
__________________
Steve
Maineroads is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 03:38 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014