950 Supermoto Turbo Build Thread - Page 5

omnivore · 02-09-2011, 06:45 PM

Quote:

Originally Posted by Tommy_J

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

Tommy_J · 02-09-2011, 06:55 PM

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.

.

snowhawk jockey · 02-09-2011, 07:53 PM

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...

Tommy_J · 02-09-2011, 08:11 PM

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.

snowhawk jockey · 02-09-2011, 09:13 PM

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.

Tommy_J · 02-10-2011, 07:23 AM

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.

.

Quedok · 02-10-2011, 03:10 PM

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.

Tommy_J · 02-10-2011, 08:04 PM

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.

Tommy_J · 02-10-2011, 08:41 PM

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.

.

Tommy_J · 02-10-2011, 09:41 PM

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.
.

Tommy_J · 02-11-2011, 05:57 PM

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.

.

Tommy_J · 02-11-2011, 09:30 PM

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!

.

Tommy_J · 02-11-2011, 10:13 PM

The EX-KTM header.

.

Tommy_J · 02-12-2011, 09:14 AM

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.

Maineroads · 02-12-2011, 09:21 AM

What do you do for a living Tommy?

02-09-2011, 06:55 PM	#62
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 07:33 PM

02-09-2011, 07:53 PM	#63
snowhawk jockey Slack Jaw Gaper Joined: Jul 2005 Location: The other Center of the Universe: Bend, Oregon Oddometer: 757	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... __________________ KTM 950 SliderMoto with 19/17 spokes, FCR41's, 2-into-1 high pipe, single side front brake and handcut flattrack style tires. Gettin Slideways is good! justin@giantloopmoto.com www.giantloopmoto.com snowhawk jockey screwed with this post 02-09-2011 at 07:59 PM

02-09-2011, 08:11 PM	#64
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 +

02-09-2011, 09:13 PM	#65
snowhawk jockey Slack Jaw Gaper Joined: Jul 2005 Location: The other Center of the Universe: Bend, Oregon Oddometer: 757	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. __________________ KTM 950 SliderMoto with 19/17 spokes, FCR41's, 2-into-1 high pipe, single side front brake and handcut flattrack style tires. Gettin Slideways is good! justin@giantloopmoto.com www.giantloopmoto.com

02-10-2011, 07:23 AM	#66
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 +

02-10-2011, 03:10 PM	#67
Quedok Gnarly Adventurer Joined: Sep 2006 Location: Long Beach, Ca. Oddometer: 183	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.

02-10-2011, 08:04 PM	#68
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 +

02-10-2011, 08:41 PM	#69
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 +

02-10-2011, 09:41 PM	#70
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 +

02-11-2011, 05:57 PM	#71
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 +

02-11-2011, 09:30 PM	#72
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 09:36 PM

02-11-2011, 10:13 PM	#73
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	The EX-KTM header. . Attached Images __________________ Current Stable : 950SM Turbo! GSXR1000 RT-P1100 VFR800 RXC620 motard EXC520 CR500AF CRF450R Plated! CR250 Past stable : 90 +

02-12-2011, 09:14 AM	#74
Tommy_J ^OP won't drive a car Joined: Apr 2007 Location: So Cal Oddometer: 336	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 +

02-12-2011, 09:21 AM	#75
Maineroads Ridgerunner Joined: Jun 2007 Location: Peak of the Valley, Maine Oddometer: 825	What do you do for a living Tommy? __________________ Steve

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