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Old 02-15-2011, 08:27 PM   #91
Tommy_J OP
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Here is an attempt at a bracket to support the tube near the turbo. It's a really 3D part. The tube slopes up and out and has a bend there.



The idea is to support the turbo by the stock KTM exhaust mount up front and by the KTM muffler mount in back. A decision on if this bracket can be used will come after the tubing is welded up more.

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Old 02-16-2011, 06:06 AM   #92
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Very nice work. The brackets and joints look OEM...
Are you gonna ceramic coat it all when it's done?
The turbo is a long way from the exhaust ports, where efficiency is concerned. A major source of energy for the turbo will be exhaust heat, in addition to flow. The ceramic coating will help to contain the exhaust heat to help aid turbo spoolup. There is a hotter version of ceramic coatings called turbo-kote. It's black, and can even be used on turbine housings and wategates, inside and out.
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Old 02-16-2011, 07:20 AM   #93
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Swoon! What work! Any interest in a DRZ-SM experiment? I can come over... it is carbed though maybe. A megasquirt setup as well
I am subscribing to this thread.
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Old 02-16-2011, 07:59 AM   #94
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Quote:
Originally Posted by LeChatNoir View Post
Swoon! What work! Any interest in a DRZ-SM experiment? I can come over... it is carbed though maybe. A megasquirt setup as well
I am subscribing to this thread.
One of my other lurking zones is Supermoto Junkie and member unclebob did a thread for his DRZ-SM turbo build:
http://www.supermotojunkie.com/showt...light=unclebob

Here is Turbo 2.0 of unclebob's project:
http://www.thumpertalk.com/forum/arc...t-683446.html&

Tommy, the slip fit joints are very streamline. I wondered how those made a seal, thanks for the explanation.

snowhawk jockey screwed with this post 02-16-2011 at 11:23 AM
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Old 02-16-2011, 01:25 PM   #95
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Old 02-16-2011, 07:37 PM   #96
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Quote:
Originally Posted by omnivore View Post
Very nice work. The brackets and joints look OEM...
Are you gonna ceramic coat it all when it's done?
The turbo is a long way from the exhaust ports, where efficiency is concerned. A major source of energy for the turbo will be exhaust heat, in addition to flow. The ceramic coating will help to contain the exhaust heat to help aid turbo spoolup. There is a hotter version of ceramic coatings called turbo-kote. It's black, and can even be used on turbine housings and wategates, inside and out.

I probably won't go the ceramic coating route, at least not at first. Its hard to do repair/rework with that coating, and it'll probably cost as much as the turbo did. Anyway, I have a couple of special tricks in mind to avoid turbo lag and I hope to get to work on them soon.

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Old 02-16-2011, 07:46 PM   #97
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Quote:
Originally Posted by snowhawk jockey View Post
One of my other lurking zones is Supermoto Junkie and member unclebob did a thread for his DRZ-SM turbo build:
http://www.supermotojunkie.com/showt...light=unclebob

Here is Turbo 2.0 of unclebob's project:
http://www.thumpertalk.com/forum/arc...t-683446.html&

Tommy, the slip fit joints are very streamline. I wondered how those made a seal, thanks for the explanation.

I remember reading every post in Uncle Bob's first thread back in 2006. Honestly, it was probably his project more than anything else that got me spun up to do this one. I'm not sure his project was a 100% success so I can't wait to read the redux thread.

Uncle Bob, if you ever read this I dedicate this thread to you!

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Old 02-16-2011, 08:08 PM   #98
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Exhaust pipe clearance to the tire should work out OK. There was insufficient clearance with the mud guard so it needed a little trim on one side. During removal a bolt snapped. Are KTM fasteners made out of cheese? Repaired with a larger fastener.





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Old 02-17-2011, 07:05 AM   #99
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Installed

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Old 02-17-2011, 08:48 PM   #100
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Some more welding was accomplished and a heat shield added. Its actually more camouflage/styling than heat shield. As I said before, I wanted to build a sleeper.

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Old 02-17-2011, 11:30 PM   #101
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I dunno how a modified orange motorcycle qualifies as a sleeper, but I don't care
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Old 02-18-2011, 04:24 AM   #102
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Didn't look like much trimming on the rear fender/mudflap, think there will be any clearance issues when the suspension compresses?
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Old 02-18-2011, 02:14 PM   #103
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I have a question (and probably a stupid one), but have you thought about using an exhaust flex joint where your slip joint is located now? Any problems with doing that?
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Old 02-18-2011, 05:29 PM   #104
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Quote:
Originally Posted by PhiSig1071 View Post
Didn't look like much trimming on the rear fender/mudflap, think there will be any clearance issues when the suspension compresses?

Clearance is ample now. That brake line is another matter though.
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Old 02-18-2011, 05:48 PM   #105
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Originally Posted by NONo443 View Post
I have a question (and probably a stupid one), but have you thought about using an exhaust flex joint where your slip joint is located now? Any problems with doing that?
That would work, but its hard to think of any great advantage to it.

A flex joint would not have fit were the slip joint was, plus it costs money.
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