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

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    As a guide on how to design a muffler I dug up these pics. When this SM was two days old I cut the muffler open and "de-catted". The results were very satisfactory, but as I said before I like my bikes quiet.

    [​IMG]

    While the mufflers were cut open the baffle design was visible. It's hard to see, but there are three baffle tubes separating the muffler into two chambers. After that the exhaust flows out one tail pipe. BTW, that thing on the right is the catalyst. I was surprised how small it was.

    [​IMG]

    My objective is to package a similar design into this space.

    [​IMG]
    #41
  2. cpallen

    cpallen Nearly Adventurer

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    And you are doing a great job! I'm riveted and don't even like KTMs.
    You are obviously a brilliant craftsman.
    #42
  3. Tommy_J

    Tommy_J won't drive a car

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    The only thin wall pipe of the right diameter I could scrounge up easily was fencing material. Its very low strength alloy. That's fine though because it easier to form bell mouths on the the baffle tubes.

    Here the pipe is being rolled around breaker bar handle.

    .

    Attached Files:

    #43
  4. Tommy_J

    Tommy_J won't drive a car

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    BTW, this was the plan for the first tube in the muffler. It has a taper the fits tight against the turbine housing and that's what really locates the muffler. That reduces stress on the three little ears which just snug the muffler against the turbo.

    .

    Attached Files:

    #44
  5. snowhawk jockey

    snowhawk jockey Slack Jaw Gaper

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    I sure would like to sponsor the materials for a second get'up mount and tubing, since yer just slappin' it together so quick. Of course, I would have to save up extra to buy the matching whistle, but I could manage. Then I would just have offer to mount it on my bike, you know, fer the sake of enjoy'in it. :wink:

    Wadda'ya say, shall I start flooding your paypal account with $1 biils?:deal

    All right I'll stop bother'in ya with nonsense and let you get the real work done.
    #45
  6. Tommy_J

    Tommy_J won't drive a car

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    Thanks for the thought. I never had any intention to make more KTM turbos but... things keep coming up that make me think "Wow I coulda made it better this way" or "Damn I wish I had a do over". Case in point, the muffler design. Its all angles and everyone of them different. I feel like a carpenter trying to trim out a room where every wall is at a different angle. Major pain in the but.
    #46
  7. Tommy_J

    Tommy_J won't drive a car

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    When the turbo position was decided on I assumed I could find a hose with an appropriate tapered 90 degree elbow. Well I just paged through the radiator hoses at Autozone.com. They show 10 hoses per page and have 79 pages. I found what I needed but of course it was on page 70. So I looked at about 700 hoses. That's about it for today's progress.

    Attached Files:

    #47
  8. anotherguy

    anotherguy Long timer

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    Not cheap but the best for turbos.
    #48
  9. Tommy_J

    Tommy_J won't drive a car

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    Nice. If I'd know about that site I might have actually coughed up the $62. Autozone's was only $10 but I lost a whole evening searching. Using radiator hose for the charge tube is actually not a concern. On a bike peak boost will probably never last more than 10 seconds, with me riding anyway. That's not long enough to get really hot. I have a car with a Novi blower and the continuous boost gets the pluming too hot to touch.
    #49
  10. Quedok

    Quedok Been here awhile

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    I hope you don't plan on using that rubber radiator hose for your compressor discharge. It will not stand up to the high temperatures that the turbo puts out under boost. You should look into a molded silicone hose or possibly a cast aluminum one if you need such a tight radius elbow. Trust me on this one.
    #50
  11. MODNROD

    MODNROD Decisions, decisions

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    I agree with the rubber hose on compressor discharge.
    I used one on my 15lb dragbike for two seasons no worries.
    It lasted on the street for one trip across the city.....

    Heat-proofing......perhaps investigate the turbine wraps, I have used curved 2mm ally plate before to make a heatshield (2mm alloy, then rolled over exhaust wrap, the 2mm alloy.....makes up a flexible sandwich construction heatshield, really cheap, pop-rivet together). If you use stainless pipe into the turbine, you can wrap the last foot for extra protection without corrosion effects.

    PLEASE, please, please, could you give me an Ebay link to these "Chiturbo's"? I have looked, but can't seem to find it. I've got 3 turbo's in the shed and 2 blowers, and ALL of them aren't quite right for my bike.

    Have fun man! (Living vicariously thru ur work coz I don't have the time myself!) :lol3
    #51
  12. Tommy_J

    Tommy_J won't drive a car

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    I think I'll be OK with the rubber hose in this application. Three reasons why are :

    1) With this setup it won't be getting a lot of radiant heat from the headers, like most turbo bikes
    2) I'm definitely planning to water inject! I love love water injection
    3) At the low boost I'm planning the turbocharger outlet temp should peak around 99 C or 210 F. Radiator hose is made for more than that.

    I may be wrong and time will tell. Inputs are much appreciated in any case.

    Modnrod, here is an ebay seller that has never disappointing me and has a lot of stuff

    http://stores.ebay.com/ETD-Motors?_rdc=1

    .

    Attached Files:

    #52
  13. Tommy_J

    Tommy_J won't drive a car

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    Oops, I just caught that I put 20 pounds boost in the calculator. I meant to put in 6 psi boost + 14.7 psi atmospheric pressure ~ 20 psi absolute.

    So actually the turbocharger outlet temp is quite a bit less - under 150 F.
    #53
  14. Tommy_J

    Tommy_J won't drive a car

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    OK Que and Mod I made a pipe just in case the rubber elbow ever fails. Its a backup plan because it won't flow as well as the elbow and would use a "non-standard" sealing arrangement.

    .

    Attached Files:

    #54
  15. Tommy_J

    Tommy_J won't drive a car

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    Most of the parts for the muffler have been "kitted" and welding will begin soon. It should flow just a bit better than one stock KTM muffler. That's what I want. Its pretty well established in Orangecrush that the single muffler mod increase bottom end torque and responsiveness with little penalty up top. And any top end penalty that did exist could be compensated for by dialing in boost.
    .
    [​IMG]

    Making all the folds properly when each angle is unique was a pain. Live and learn.
    .
    [​IMG]
    #55
  16. MODNROD

    MODNROD Decisions, decisions

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    There's a lot of fabrication to do anything like this, but you have the skills obviously and the talent, so making the stuff is most of the fun anyway.
    Don't stress about the rubber hose mate. It's like tuning the bottle......when it
    gets rough under power, back it off a jet or two, then close your eyes when you change the plugs next! :deal

    Thanks very much for the link man, much appreciated.:clap
    #56
  17. D.T.

    D.T. Difficult but useful

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    :clap
    #57
  18. omnivore

    omnivore SuperSportTourer

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    For an aesthetically pleasing turbine heat shiled, go to walmart. FInd a cheapo stainless steel cooking pot in a diameter about 1/2"-1" larger than the exhaust housing. Cut the sides off the pot to clear the exhaust discharger, and then mark and drill holes to mount it to the exhaust housing bolts.

    Here's a how to with pics: I did this on my last Omni. Cheap, effective, and attractive.

    http://www.supraforums.com/forum/showthread.php?326366-DIY-Turbo-Heat-Shield-write-up-with-pics.
    #58
  19. Tommy_J

    Tommy_J won't drive a car

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    Very nice idea. That looked like a big assed turbo. I'd have to start with a little soup pan.

    .
    #59
  20. Tommy_J

    Tommy_J won't drive a car

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    Muffler welding in progress. Usually in a turbo build the muffler is the last thing dealt with, an after thought. I need to build one first since its how the turbo is mounted to the bike.

    Maybe I won't finish the muffler 100% but start using it as a hanger when its tacked welded together. I want to move on and make headers instead of dicking around with this muffler.

    .

    Attached Files:

    #60