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Old 02-18-2011, 06:00 PM   #106
Tommy_J OP
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The one, and probably only, purely cosmetic part is a tail pipe. It mirrors the profile of the muffler with a little slash cut.





After this is welded on everything comes apart for some silver paint.

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Old 02-18-2011, 06:50 PM   #107
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Quote:
Originally Posted by Tommy_J View Post
Clearance is ample now. That brake line is another matter though.
I have a theory on how to handle the brake line clearance issue. I'll be in the garage for a bit making sure I am not talking out my exhaust.
It will not be a "perfect and sano" solution until the brake line is altered, but it will be workable for testing and street riding.

I found unclebob's email and I will be inviting him to follow the thread. His second system is rear mount, like your's, in case you haven't had a chance to read the thread on TT. I haven't finished reading the second build thread, so I don't know all his facts.

Edit:
After a bottle and some test wrenching in the garage, I found a work around for you. Flip the banjo fitting over and feed the line from under the master cylinder mounting tab:



I can't test ride the setup, but I am confident it could serve for at least medium swingarm travel riding. If I was really competent, I would pull the shock and move the swinger through its full travel to check if the line binds anywhere. Maybe this could serve your testing purpose.

eedit:

If you haven't found out yet, there is no disconnect plug under the rubber cap on the rear brake light switch cable. The wires are molded in and twist right off with finger pressure so be more careful than I was.

snowhawk jockey screwed with this post 02-18-2011 at 08:37 PM
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Old 02-19-2011, 08:26 AM   #108
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Snow, That's a great idea. I'll try it today. The clearance problem is a little worse than just the brakeline/pipe. The turbo's oil drain is huge also needs to pass through that area, so I need all the space I can get.

Thanks for the idea!
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Old 02-19-2011, 08:10 PM   #109
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I don't mean to turn this into a "haul" thread but shopping for materials is taking almost as much time as actually building this project. Well, that is if time specing the materials out is included. Some days the only progress is gathering up stuff.

Here is $42 dollars in gasket materials.



And here is $22 dollars in hose. This is actually the third such batch.

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Old 02-19-2011, 08:21 PM   #110
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The forward turbo support is welded on. It mounts to the frame exactly as the KTM exhaust did. It seems nice and sturdy so the other support bracket that held the turbo up this point can be deleted.

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Old 02-20-2011, 06:43 AM   #111
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You still have a rear mount though?

Sometimes, especially on a length of exhaust pipe, you can resonant tuning thru the pipe at steady cruise revs (sometimes called drumming inside a sedan with a big pipe), and this can actually cause stress fractures if resonance and also a bit of weight swinging around is put together.

Lookin good man. It's all very exciting!
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Old 02-20-2011, 08:34 AM   #112
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Quote:
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You still have a rear mount though?

Sometimes, especially on a length of exhaust pipe, you can resonant tuning thru the pipe at steady cruise revs (sometimes called drumming inside a sedan with a big pipe), and this can actually cause stress fractures if resonance and also a bit of weight swinging around is put together.

Lookin good man. It's all very exciting!
Thanks Mod. I never showed a pic of the temporary bracket. This is an early picture and the bracket is in the middle. It does not have rubber for compliance. If a stiffer support is ever needed I'd probably come up with a rubber mount and put this bracket back on. Its pretty heavy, 1/4" steel.

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Old 02-20-2011, 11:07 AM   #113
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The Turbine housing got a polishing. Rustoleum paint applied and cured in a 3 step process following directions on the can. The last step was hot enough to turn the steel inside the muffler a beautiful gun blue color. The paint feels hard like ceramic but only time will tell how smart it was to use paint.

Gaskets were cut and this final assembly of the "hot" parts is complete. Making the gaskets was actually a big PIA because there is a layer of sheet metal in there.

It feels great to have something that looks like a turbo all done but 2/3 of the real work still lays ahead.




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Old 02-20-2011, 12:01 PM   #114
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beautiful.
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Old 02-21-2011, 09:59 AM   #115
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Do the oil lines tap in to the two threaded ports on the outboard side of the turbo? Where will they feed/return the oil from? How's the plenum coming? How is fitting it into the under profile of the tank working out?
What are you doing with all the cable routing that runs along the airbox?

Sorry for the questions, had too many whistling dreams last night...
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Old 02-22-2011, 07:29 AM   #116
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Hi Didjoe, Thanks!

How is your turbo coming along?

Next, I will do the oil plumbing and I'm concerned the simple plan may not work. Did you have to use an electric scavenge pump to get the oil back in the tank?
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Old 02-22-2011, 07:35 AM   #117
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Quote:
Originally Posted by snowhawk jockey View Post
Do the oil lines tap in to the two threaded ports on the outboard side of the turbo? Where will they feed/return the oil from? How's the plenum coming? How is fitting it into the under profile of the tank working out?
What are you doing with all the cable routing that runs along the airbox?

Sorry for the questions, had too many whistling dreams last night...
Snow, The ports visible on the side of the turbo are for water cooling and won't be used. The oil inlet is at the top and visible in the last picture. Also in that picture is a beginning of the intake plenum. Theres a long way to go on that project!
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Old 02-22-2011, 11:04 AM   #118
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Great build thread

Cant wait to se the finished product.

(I wish I had .01% of the fabrication skills that you have - nice work!)
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Old 02-22-2011, 11:19 AM   #119
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That looks amazing! Can we see a picture of a test fit with the plastics on??? I think you've managed to make it stealth!

I'm waiting to hear that thing running!
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Old 02-22-2011, 04:34 PM   #120
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Thanks for the encouragement!

Here is a oil flow diagram from the service manual. Oil under the circular filter cover is at full galley pressure so I tapped in there to get oil for the turbo. It seems like KTM made that cover ready to accept a 1/8 NPT fitting. I just drilled and tapped the casting.






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