950 Supermoto Turbo Build Thread

Discussion in 'Some Assembly Required' started by Tommy_J, Feb 2, 2011.

  1. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal

    OK. Change of plans already. To build the header I wanted all the end points fixed in space first. This temporary bracket was not holding the turbo securely enough. Sooo, I’m going to build the muffler first. The reason why is this muffler will double as the turbo mount. It will pick up the standard KTM muffler mount at the back.


    Here’s a posterboard pattern. I’m getting bold with styling here and going after somingthing like the ZARD mufflers.

    .

    Attached Files:

    #21
  2. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Turning posterboard into metal. Its just mild steel. I have no desire to use fancy alloys because this bike will get ridden. It may even get dropped someday and mild steel is easier to fix.

    .

    Attached Files:

    #22
  3. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    .

    Attached Files:

    #23
  4. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Its a funky KTM angular style. Hopefully I won't regret this.

    .

    Attached Files:

    #24
  5. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Its still extra big. Trimming will come later. Objectives included quiet and stealth so I might leave it kind of big.

    .

    Attached Files:

    #25
  6. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Muffler/turbo hanger

    .

    Attached Files:

    #26
  7. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Anybody know the secret to uploading more than one pic at a time?

    Here is the muffler's interface with the turbo. Sorry about the focus.

    .

    Attached Files:

    #27
  8. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    The plan is for studs from the muffler to go through the turbo exhaust housing. Unfortunately the housing has blind holes so I need to cut away some of the housing.

    ,

    Attached Files:

    #28
  9. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    ,

    Attached Files:

    #29
  10. cpallen

    cpallen Nearly Adventurer

    Joined:
    May 26, 2003
    Oddometer:
    1,009
    Location:
    Seattle, WA
    If you put your pictures up on a hosting site like FLICKR.COM you can use the insert Image tool (looks like mountains)

    [​IMG]

    With flickr, you click on the picture and select the size (the above is 640 medium). Here's their FAQ about it: http://www.flickr.com/help/photos/#2265887

    [​IMG]

    Don't know what the limit is, if any. I hope this helps your cool project.

    Attached Files:

    #30
  11. Chillis

    Chillis Land Barge Pilot

    Joined:
    Aug 25, 2005
    Oddometer:
    4,229
    Location:
    Spring Mountain Range
    For pictures I use a Facebook account just for pictures. No personal info or anything.
    #31
  12. OaklandStrom

    OaklandStrom Long timer

    Joined:
    Sep 17, 2005
    Oddometer:
    1,618
    Location:
    East Bay
    If you are uploading from your computer, the limit is one at a time.
    If the hosting is done elsewhere (Smugmug, Flickr, Facebook...) you can attach multiple pix to a post.
    #32
  13. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Thanks for the advice on posting pics. The exhaust housing has been machined to make ears the muffler can bolt to. While I was at it I machined some excess metal out of the housing. Then the entire housing was sanded with a flapper wheel until smooth. This way it will look good if I ceramic coat it.

    .

    Attached Files:

    #33
  14. snowhawk jockey

    snowhawk jockey Slack Jaw Gaper

    Joined:
    Jul 5, 2005
    Oddometer:
    1,154
    Location:
    The other Center of the Universe: Bend, Oregon
    Well now, just get right started, why don't ya!
    Dig the one piece mount, muffler and masking.
    The muffler profile is so "stock" looking, just paint it flat black when you are done to compete the appearance.:rofl Might want some extra heat reflector on the side panel to keep it from melting, its gonna get a bit hot under there.

    Probably want a shield where turbine body protrudes too, otherwise you will get the classic KTM dirtbike pants/boot burn.

    Thinking of moving heat, would ceramic coating the inners of your muffler box and core help lower temps around/outside the box?
    #34
  15. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Snow, Your right, some thought and effort will have to go into heat management!

    The part of the "muffler" that goes over the turbo will probably become part of a heat shield.
    #35
  16. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    Alright lets see if I can upload images from a host.

    Here is a series showing development of that muffler bracket. It was laid out on poster board, test fit, re-laid out, re-tested, modified some, transferred to steel, band sawed out, folded, and tack welded in place. A pleasant 20 minute job.

    .
    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]

    [​IMG]

    [​IMG]
    #36
  17. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    The length of the muffler was trimmed down, front and back. It got a serious slash cut. Maybe longer would have looked better but the turn signal was in the way. I considered making a new tail tidy type thing to move the turn signals, but that's the sort of scope creep that would set the project back a week.

    Just to state the obvious, this is a mock up. Its not done by any means.

    .

    Attached Files:

    #37
  18. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    The metal cut off the turbo end of the muffler will be saved to make a heat shield latter. Hence the notch around the wastegate arm.

    .

    Attached Files:

    #38
  19. cpallen

    cpallen Nearly Adventurer

    Joined:
    May 26, 2003
    Oddometer:
    1,009
    Location:
    Seattle, WA
    Put each image link on it's own line, and you can insert your descriptive text in between eg:

    [IMG link # 1]
    [​IMG]

    yada yada yada
    The length of the muffler was trimmed down, front and back. It got a serious slash cut. Maybe longer would have looked better but the turn signal was in the way. I considered making a new tail tidy type thing to move the turn signals, but that's the sort of scope creep that would set the project back a week.

    Just to state the obvious, this is a mock up. Its not done by any means.


    [IMG Link #2]
    [​IMG]
    more description

    [IMG Link #3]

    etc
    #39
  20. Tommy_J

    Tommy_J won't drive a car

    Joined:
    Apr 1, 2007
    Oddometer:
    338
    Location:
    So Cal
    CP, will do. This is my first build thread - ever. I'm learning as I go.

    :norton
    #40