FJ1289 suggested I put together a build thread. The day by day, blow by blow account of the build is detailed on a British site called 'Oldskoolperformance.com' but I think the engine mods especially may be of interrest to you guys.
I had rode the FJ on the road for several years then used it on the Drag Strip for a few more years but retired it. The story started after a stoopid crash at Santa Pod Drag strip on my 1340 Slingshot, ripped my toe off and had to sell the bike on as it was half my brothers and he wanted out after the crash.
Me doing a 'FISH' and ripping my big toe off. Santa Pod Oct '09, doh. (http://www.youtube.com/watch?v=Ff4gtfq5Hns#)
Rooky, mistake, swapped to Micky T's and didn't take it into account on launch..doh.
So, need a new race bike, old FJ motor was a pearl, use that.
(http://i214.photobucket.com/albums/cc122/cabletietom/oldFJdoingthebiz.jpg)
Needed it to be street legal for the class I was intending to race. Couldn't be legal in original FJ chassis because of government legal bollox that isn't important here. I did have an old motorless 750 Katana in the shed that was still registered though, simple engine swap it is then. Was going to be NA to begin with but the motor was taller and had a wider sump that the original Suzook so some surgery was neccesary. Bottom frame rails cut out..
(http://i214.photobucket.com/albums/cc122/cabletietom/bottombackinrightplace.jpg)
and new ones fabbed up.
(http://i214.photobucket.com/albums/cc122/cabletietom/Copy2ofkat021.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/P1010236.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/08012011273.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/08012011272.jpg)
now the motor
Bought a 1500cc block and JE pistons from a company called BigCC here in England, but they are OrientExpress I believe. Sent the head and crank cases of to be breathed on. Top cases opened up to accept block and +2mm on both inlet and exhaust.
(http://i214.photobucket.com/albums/cc122/cabletietom/Katboredoutcases1.jpg)
Flowed the head as well.
(http://i214.photobucket.com/albums/cc122/cabletietom/Katflowedheadinlet.jpg)
Now the headers. Made up some collets out of 10mm Ally plate.
(http://i214.photobucket.com/albums/cc122/cabletietom/Katheadercolletspattern.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/Katroughcutexhaustclamps2.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/Katexhaustclampsfront.jpg)
Headers had to be off set very slightly as I'd offset the motor by 5mm for the chain run. Headers made from stainless originally destined for a milking parlour.
(http://i214.photobucket.com/albums/cc122/cabletietom/Katheadermockup.jpg)
Had to make some split ring collets for the pipes as the frame rails were too close to the motor.
(http://i214.photobucket.com/albums/cc122/cabletietom/collet12.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/collet16.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/Headers1.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/Headers2.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/Katheaders4.jpg)
Got to go pick up daughter, continue when I return..
Incidentally, front end is FZR1000 Genesis forks and triples with a GSX1100F Suzuki stem(Powerscreen model). Genesis wheel, chrome effect powder coat, with R1 Callipers on original rotors. The Genesis front end was a direct swap into the FJ originally, might have missed out a lock nut, just had to swap the stem out for the Suzuki Head Stock.
The rear is also Yam, was originally a Genesis arm and wheel, needed swap out the wheel to go 17" for the rubber but the 18" Genesis wheel was excellent on the road. And the arm went to be replaced by a Harris arm of the correct vintage for the Kat, which I then lengthened and braced a bit. Still to make the Calliper mounting plate.
On with the motor. Had the crank, box everything checked by a company called SEP Engineering. As good and as strong as they can be. FJ limitations being the strength of the crank.
(http://i214.photobucket.com/albums/cc122/cabletietom/Katcrankcheckedwithrods2.jpg)
The Carillos were going to prove a problem on build up. Time to put the plot together. Is everything still there (2 years at this point).
(http://i214.photobucket.com/albums/cc122/cabletietom/20120310_142409.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20120406_190838.jpg)
The bolts on the rods caught the cases enough to stop rotation by hand.
(http://i214.photobucket.com/albums/cc122/cabletietom/20120422_141548.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/DSCN2242.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/DSCN2241.jpg)
You can see the contact mark.
(http://i214.photobucket.com/albums/cc122/cabletietom/DSCN2240.jpg)
Took enough metal off cases to allow for heat expansion, really wasn't much, no issue with continuity I think.
Supplied manuel cam chain tensioner from APE was an issue with the big block, had to grind it down to fit.
(http://i214.photobucket.com/albums/cc122/cabletietom/DSCN2245.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/DSCN2244.jpg)
This was last Easter.
I had tried to cure the documented 2nd gear issue by swapping out the 1100 box for a later 1200, I've had the dogs and cogs x-rayed and there doesn't seem to be an issue, guess I'll find out one way or another down the road. The box wasn't able to be undercut like all my Suzooks as they're a differnt shape, please tell me if I'm being an idiot, I have to take people at their word as I'm not an engineer, the guys explaination made sense when he said it...
(http://i214.photobucket.com/albums/cc122/cabletietom/20120608_132649.jpg)
Because I've had issues with Yam clutches in the past, I've worked of the FJ one a bit. Falicon bilet basket(had an EXUP one explode) and a Barnett spring ajustment so I can use the lock up.
(http://i214.photobucket.com/albums/cc122/cabletietom/Clutchtogether.jpg)
With all the new valves, head work, shims were going to be needed.
(http://i214.photobucket.com/albums/cc122/cabletietom/20120608_130334.jpg)
And there we are, top end oiler by HSR on your side of the pond, works for me but won't fit in an FJ chassis I don't think.
(http://i214.photobucket.com/albums/cc122/cabletietom/20120726_141514.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20120726_141535.jpg)
Well if that isn't an interesting project, I don't know what is. Some days I feel like I know a thing or two, but then I see things like thus and realize there's still a lot to learn.
Thanks for sharing.
Great build, very cool, can't wait to see the finished product and your dyno numbers.
The dogs on the gears are what is undercut, preventing separation under load. Randy @ RPM has undercut gears for you and at your power level you're gonna need them. I don't know what you mean about the "box" being undercut, I have not heard of that.
Were you able to save your toe? Ouchy! Cool build, keep the pictures coming! Cheers. Pat
Quote from: Pat Conlon on October 25, 2012, 01:01:42 PM
Great build, very cool, can't wait to see the finished product and your dyno numbers.
The dogs on the gears are what is undercut, preventing separation under load. Randy @ RPM has undercut gears for you and at your power level you're gonna need them. I don't know what you mean about the "box" being undercut, I have not heard of that.
Were you able to save your toe? Ouchy! Cool build, keep the pictures coming! Cheers. Pat
The way the dogs on the GSXR gears are I can see how to cut them down so as power increases, they lock themselves tighter together. Need to learn how to do this with the different shaped dogs on the FJ, need to shearch the forum I guess.
Toe...
(http://i214.photobucket.com/albums/cc122/cabletietom/damagedfoot002.jpg)
all good now though, national health system does work :)
I have arrived at the font of knowledge too late it seems. I'm going to use this motor as is because I've run out of money. I'm quite happy that it'll cope, gear box-wise, with the low numbers I'm going to put through it initially, 200+ ish. My Hero Bob S, put quite alot through standard stuff before he got poorly.
Really want to know how to undercut these dogs, and have a discussion with the guys that said 'won't work', need to see one done first though.
When they bugger up they leave a big radius on the end so they just roll out of position.
Dogs are initialy cut square at 90 deg so they are the same size at the base and at the tip.Undercuting them reduces the width at the base and leaves the tip alone.Might be a 5 deg angle on either side not sure didnt measure mine.Might be .100" smaller across the base.
Always undercut the dogs on the GSXR, I know the score engineering wise how and why. Was just told these weren't worth doing as it wouldn't suffer from the same affliction. Could well have been hoodwinked, but they talked themselves out of money if it's true ,they are quite well respected? Happy with the ability of this set up atm, need to dig deeper when I put a decent BB turbo and an Intercooler on to up the boost.
Might as well do it now imo.The shift forks get bent the later year forks are stronger,you want those if you dont have them.
I waited a month or so on my first fj and when I did it I wished I had done it sooner.Had an undercut trans sitting there waiting.
If you have all the parts ready it takes less than a day.
I did both my bikes well worth it :yahoo:
My opinion, unless you enjoy removing the motor, and splitting the cases do it now while the motor is out. With the work you are doing it sure would be a shame to be have a missing tooth in an otherwise pretty smile.
Dan
Quote from: Dan Filetti on October 25, 2012, 05:15:35 PM
Unless you enjoy removing the motor, and splitting the cases do it now while the motor is out.
Agree Dan but I only got to earlier this year with the up loads, motor is well finished and in,just doing the wiring now. I really do enjoy spliting motors, got quite a few of them FJ, GSXR etc in various states of build. althought I'd rather it didn't explode. I genuinely think with this first incarnation the plot will be fine, still struggling to see how the uncut I did on the Suzooks could work here, the whole thing meshes differently. There will be a way of making it better, someone will have done it before and hopefully I'll get details on it and it will be done. This cluster will be fine for now though. Over 250 and that's a whole new ball game.
(http://i214.photobucket.com/albums/cc122/cabletietom/20120726_181142.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/Throttlebodiesetc.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/Secondarybutterflyremoval1.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20120827_215151.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/oilfeedtakeoffs2.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/KMSMD351.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/KMScoilpack.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/KMS-400KpaMAPsensor.jpg)
...........
and the first attempt at modding to go faster in 1982 at the age of 15, PC50, 62cc FS1E motor, Micron Expansion Chamber, YB100 carb, C90 back end. No real brakes :crazy:
(http://i214.photobucket.com/albums/cc122/cabletietom/fs1e.jpg)
Very scary ride...
Also need to talk to 'Randy'... :good2:
Quote from: Havoc on October 25, 2012, 01:50:51 PM
Toe...
(http://i214.photobucket.com/albums/cc122/cabletietom/damagedfoot002.jpg)
all good now though, national health system does work :)
And that is with proper gear, wow!
awesome build, , would allow you to do the same to my Fj engine , if you pay for it :lol:,, so how did you manage to damage your foot, , slip off the peg and drag, , have an off , , however it happend glad it wasn't worse :hi:
Quote from: fj11.5 on October 25, 2012, 08:45:56 PM
awesome build, , would allow you to do the same to my Fj engine , if you pay for it :lol:,, so how did you manage to damage your foot, , slip off the peg and drag, , have an off , , however it happend glad it wasn't worse :hi:
The accident is shown in post 1, flipped the old race bike off the line and it came down on my foot, peg went through my MX boots. Fine now.
Hell , flipping the bike I can understand, but what are the odds of a peg being impaled on your foot, hope you bought a lottery ticket
Might want to ask John Hopkins about that, he had a peg go where the sun don't shine in one of his many crashes.... Damn, that's got to hurt.
Faaaark :shok: , who did he piss off to deserve that, , think is rather have a toe mangled :scratch_one-s_head:
:biggrin:Ive just posted a pic of your bike in the general discussion section (warning fj12 chop...).
I didnt realise you were a poster on here!
Its great to see what youve done with your bike,i love it.
Im tempted to put a spare fj engine into one of my spare unengined GSX11EFE's (gs1150e). Then to cause head scratching as to what's he doing now,fit a spare 1127cc gsxr engine into an FJ12. People who say fit the gsxr engine into the EFE would probably reading from the easy page. I like a challenge.
I cant wait to see your bike finished. Keep up the good work.
Brett. :biggrin:
I saw thw lock up plate in one of the pics along with the spring conversion plate. I ran into problems with that setup ( MRE lock up) as the arms really dug into the aluminum conversion plate. That was with no weight attached to the arms. MTC pressure plates run steel contact buttons in the pressure plate....unfortunately they do not make a kit for the FJ.
Are you using shim under bucket in the engine? I have run into some problems with that set up too.
Quote from: JMR on October 28, 2012, 08:16:41 AM
I saw thw lock up plate in one of the pics along with the spring conversion plate. I ran into problems with that setup ( MRE lock up) as the arms really dug into the aluminum conversion plate. That was with no weight attached to the arms. MTC pressure plates run steel contact buttons in the pressure plate....unfortunately they do not make a kit for the FJ.
Cheers for your input man. This is something that I've talked alot about. The rear of the Barnett plate is quite complex and would make machining some buttons into it quite involved.
(http://i214.photobucket.com/albums/cc122/cabletietom/20120329_185150.jpg)
Barnett have stated that the hardness of the ally and the anodizing should make this one harder to damage but I agree with you, this is one of their old ones.
(http://i214.photobucket.com/albums/cc122/cabletietom/oldbarnettplate.jpg)
It will ware, fingers crossed not too fast, if it destroys it's self too quickly I'll get some steel buttons heat shrunk into the replacement :good2:
Quote from: JMR on October 28, 2012, 08:16:41 AM
Are you using shim under bucket in the engine? I have run into some problems with that set up too.
This is Shim 'over' bucket, it's the old 1100 Head
Quote from: dixiethedog on October 28, 2012, 05:50:13 AM
Im tempted to put a spare fj engine into one of my spare unengined GSX11EFE's (gs1150e).
Brett.
Do it Brett, good to see you over here :drinks:
Im very tempted. :good2: I dont know if you spotted the fj12 chop thing i posted in general discussion,but i provided my pal Robbie with a garrett turbo for that chop thing. Its going to be crazy. :biggrin:
Without taking over with too much of my ramblings,do you think the fj motor would go fairly easily into a box sectioned frame (gsx)?? I can see youve had to modify the frame rails on yours?? Its something i need to look at.
Ive 2 FJ12's,I need to go play with one..... :biggrin: Hmm....what would you think of a supercharger (pulley wheel)running from the clutch?? Do you think it would be do-able??? Ive a spare supercharger set up.... :biggrin:
There you go.....some big wear in a relatively short amount of time.
I see your point about installing inserts in the Barnett plate. The APE conversion plate is pretty simple and has a flat face....much easier to put inserts in.
I converted to shim under bucket when I installed cams in the .400 lift range. Obviously you will be using a different profile for the turbo but the sharp lobe nose of turbo grinds work well with a lighter valvetrain. Problem is the Kibblewhite Ti FJ shim under retainers "egg" out especially if you run a good amount of spring (which you need with the larger cams). This is also a problem on busa's using the Ti retainers both from Kibblewhite and APE. Somebody finally came out a bucket for the busa that holds the shim which eliminates the wear problem.
I am going to have to replace the retainers at some point. The new Kibblewhite retainers use a 9mm shim (even lighter) and I will have them either Ti nitrided or DLC treatment
Quote from: JMR on October 28, 2012, 11:54:28 AM
I see your point about installing inserts in the Barnett plate.
I think, on the back of this I'll revisit this, one of those things during the project that just fizzled out, wasn't going to be impossible, just difficult. I have been thinking through using some small suzuki valve shims in a drilled indent. A little worried about what would happen if one came loose.
Quote from: JMR on October 28, 2012, 11:54:28 AMI converted to shim under bucket when I installed cams in the .400 lift range.
Apart from the +2mm valves, HD springs and retainers from OrientExpress (always assumed Kibblewhite, but packaged in Orient bubble packs thinking about it), and the flow job, the head is stock cam-wise. My turbo man suggested that I didn't want cams that were too aggresive. If anything I was thinking about using a milder cam from a 1200 for it's initial road trim.
I am getting the feeling that I should have come here alot earlier, the FJ Owners forum in the UK is a closed club I think, I was a member briefly when I was given a years free membership for an article I wrote for their Mag. There is alot of open access info but not a forum that I can ask questions on, especially regarding one off builds. I got most of my info from Bob Sharma's site and he build draw through systems.
Quote from: Havoc on October 28, 2012, 02:16:05 PM
Quote from: JMR on October 28, 2012, 11:54:28 AM
I see your point about installing inserts in the Barnett plate.
I think, on the back of this I'll revisit this, one of those things during the project that just fizzled out, wasn't going to be impossible, just difficult. I have been thinking through using some small suzuki valve shims in a drilled indent. A little worried about what would happen if one came loose.
Quote from: JMR on October 28, 2012, 11:54:28 AMI converted to shim under bucket when I installed cams in the .400 lift range.
Apart from the +2mm valves, HD springs and retainers from OrientExpress (always assumed Kibblewhite, but packaged in Orient bubble packs thinking about it), and the flow job, the head is stock cam-wise. My turbo man suggested that I didn't want cams that were too aggresive. If anything I was thinking about using a milder cam from a 1200 for it's initial road trim.
I am getting the feeling that I should have come here alot earlier, the FJ Owners forum in the UK is a closed club I think, I was a member briefly when I was given a years free membership for an article I wrote for their Mag. There is alot of open access info but not a forum that I can ask questions on, especially regarding one off builds. I got most of my info from Bob Sharma's site and he build draw through systems.
I agree though a set of the old Yoshimura Stage 1 cams would probably work well. That is the hot set up in big turbo busa's :good2:
Quote from: JMR on October 28, 2012, 02:26:11 PM
I agree though a set of the old Yoshimura Stage 1 cams would probably work well. That is the hot set up in big turbo busa's :good2:
Love the idea of having a bit of Yoshi in the heart of it. Spent up for this stage though, it's going together as is. Just spent $2500US on the ECU and associated gubbins, that's all the brownie points with the missus used up for a while, and she think's it was $250 :diablo: . Mild tune with this little T3. Going ApeShit next build, got a little BB turbo, intercooler set up in mind.
Quote from: Havoc on October 28, 2012, 02:16:05 PM
.........If anything I was thinking about using a milder cam from a 1200 for it's initial road trim.....
I have heard in the past that the early FJ1100 cams were more aggressive than the later FJ cams, however, when Randy was doing my '84's rebuild, we looked at the 1100 vs. 1200 cams side by side, and taking measurements shows that they are the same.
Quote from: Pat Conlon on October 28, 2012, 02:49:27 PM
Quote from: Havoc on October 28, 2012, 02:16:05 PM
.........If anything I was thinking about using a milder cam from a 1200 for it's initial road trim.....
I have heard in the past that the early FJ1100 cams were more aggressive than the later FJ cams, however, when Randy was doing my '84's rebuild, we looked at the 1100 vs. 1200 cams side by side, and taking measurements shows that they are the same.
Pat you know I've never measured them, always been a belief, urban myth?, there you go. However the part numbers are different for the 1100, all the 12's have the same part number, doesn't mean they're different though I guess.
36Y Inlet - 36Y-12171-00
36Y Exhaust - 36Y-12181-00
1TX, 3CV and 3XW Inlet - 47M-12171-00
1TX, 3CV and 3XW Exhaust - 47M-12181-00
I like it here, not been able to talk to peole about FJ specific issues before, been making it up as I go along, thanks :drinks:
Lookin at that though the numerical parts of the numbers are the same, never noticed that before..
Made up the main oilcooler feedlines this afternoon. I have used the bottom section of the original cooler feed lines.
(http://i214.photobucket.com/albums/cc122/cabletietom/20120828_195753.jpg)
Cleaned up for paint.
(http://i214.photobucket.com/albums/cc122/cabletietom/oilfeedcleanedup.jpg)
I did this by welding a fixing on the top of the old pipes to accept Earls stuff.
(http://i214.photobucket.com/albums/cc122/cabletietom/mainoillines2.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/mainoillines1.jpg)
The radii of the bends are a little too tight for my liking, I think it will be stressing the fixing a bit much, we'll see. Just to say I really do appreciate the input I've had here, problem is I found this place too late, I don't have the funds to go back and retro fit better ideas at this stage, it'll be running in a month or so. But when I rebuild I can take the expertise offered here on board. Thank you folks :good2:
Hi Havoc,thats a nice looking set up on the cooler pipe work. Can i recommend;
http://stores.ebay.co.uk/Torques-U-K/AN-6-Adapters-/_i.html?_fsub=582624012&_sid=81447352&_trksid=p4634.c0.m322 (http://stores.ebay.co.uk/Torques-U-K/AN-6-Adapters-/_i.html?_fsub=582624012&_sid=81447352&_trksid=p4634.c0.m322)
if you need fitting at less cost than the big name brand stuff?? I use this company for all my stuff when it comes to hose's,AN fitting etc. Ive never had a problem yet with any of it.
Just a thought. :good2:
That is a little cheaper than Earls from Pirtek, cheers.
Not a massive Bling Fan but I've got a machine at work that engraves. The window clutch cover will be engraved. Here are some test pieces, will be going with the clear background 'Oldskoolperformance' design. The 'FastByMe' logo is a friend of mine that does ride in, ride out Turbo installs.
(http://i214.photobucket.com/albums/cc122/cabletietom/croppedOSP.jpg)
Dave
(http://i214.photobucket.com/albums/cc122/cabletietom/FastByMeclutchwindow.jpg)
Later
Fitted the new 680cc DEKA injectors into the TBs, coil pck and 4 BAR MAP sensor arrived this week as well.
(http://i214.photobucket.com/albums/cc122/cabletietom/20121116_205058.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20121116_205019.jpg)
making up the fuel system this Sat if it's not to cold in the shed. Earls SS lines in many pieces. Tank-course filter, filter-pump, pump-fine filter, filter to fuel rail, rail-rail, rail to FPR and FPR-tank. Not sure where to mount Coil pack and KMS ECU, they need to be as far apart as possible, one in the nose , one in the tail but not sure which way round to go. HT leads would be shorter if the coil was in the nose, recieve better cooling there as well.
My shed is cold and wet this time of year and has no electricity so the build has been transfered to the Turbo experts's workshop a couple miles away.
Onwards and upwards...
(http://i214.photobucket.com/albums/cc122/cabletietom/FBM2.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/FBM1.jpg)
:good2:
Seems like a tuning nightmare to me to ever start playing with alternate carb configurations, I can't imagine making all the drastic mods you're doing and still getting it to run well. I get going fuel injected does make it a little easier, though. I just feel comfortable getting a bike back to stock. Can't imagine the experience it would take to do what you're doing well. Hats off to you. :hi:
Definitely enjoying the read. (popcorn)
I'm enjoying the saga too. I'm visiting the UK next year, maybe see the beast in person?
Andy
Quote from: Havoc on November 24, 2012, 03:02:03 PM
My shed is cold and wet this time of year and has no electricity so the build has been transfered to the Turbo experts's workshop a couple miles away.
Onwards and upwards...
(http://i214.photobucket.com/albums/cc122/cabletietom/FBM2.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/FBM1.jpg)
:good2:
Thats a good place for your bike to be. :good2: One day i too hope to pay a visit to that particular person's garage armed with some cash and a few ideas. :good2:
i've been following the thread eagerly too... more detailed pictures of turbo oiling and fuelling please!! (popcorn)
keep up the good work!
Quote from: andyoutandabout on November 25, 2012, 11:07:17 AM
I'm visiting the UK next year, maybe see the beast in person?
More than welcome, will be running at the Straightliners events at Santa Pod. I'll be trundling around on it on the road in between meets. I'm slap bang center of the island near Nottingham :drinks:
Quote from: backstreetheros on November 25, 2012, 05:42:31 PM
i've been following the thread eagerly too... more detailed pictures of turbo oiling and fuelling please!! (popcorn)
keep up the good work!
Will be sorting the turbo oiling next Saturday and finishing the fuel lines, didn't take any photos of that last Sat.
I too live in England and would love to see the bike!!! :good2:
Kettles always on Brett...
3O Micron filter to pump
(http://i214.photobucket.com/albums/cc122/cabletietom/Photobucket%20Desktop%20-%20TOM-PC/Fuelline3.jpg)
Home brew fixtures. Take a perfectly good XJR FPR and hack it up.
(http://i214.photobucket.com/albums/cc122/cabletietom/Photobucket%20Desktop%20-%20TOM-PC/Fuellinebespoketakeoff.jpg)
Smooth it off, we can use that.
(http://i214.photobucket.com/albums/cc122/cabletietom/Photobucket%20Desktop%20-%20TOM-PC/Fuelline4.jpg)
A little bit of that..
(http://i214.photobucket.com/albums/cc122/cabletietom/Photobucket%20Desktop%20-%20TOM-PC/Fuelline5.jpg)
sorted
(http://i214.photobucket.com/albums/cc122/cabletietom/Photobucket%20Desktop%20-%20TOM-PC/Fuelline9.jpg)
Loopie 9 piece fuel line..
(http://i214.photobucket.com/albums/cc122/cabletietom/Photobucket%20Desktop%20-%20TOM-PC/Fuelline3.jpg)
Milk and one sugar please Tom. :good2:
Once I can get some money back in the bank,im going to try to pull things together,so I too can have a bike in the garage pictured!!! For me,messing about (which is all it is)with turbo's and bits of stainless pipe etc is probably not going to get me very far. Far better I give the man who can a carrier bag of used 20 pound notes,and ride in,ride out. :biggrin: Then,once Im in your area,it would be great if i was able to come and drool and dribble all over your bike. :lol:
i love it,i love it ilove it!!! Theres a new air cooled suzuki site online now,catering for erm..air cooled stuff,which I also love,but what a shock they'll get when i stick a yam engine into a suzuki frame. :lol: i'll be banished from the site.
Keep the good work up,and post some more please. :good2:
It would be interesting to see what FBM could do with an FJ12????
Quote from: dixiethedog on December 02, 2012, 06:30:59 AM
Theres a new air cooled suzuki site online now,catering for erm..air cooled stuff,which I also love,but what a shock they'll get when i stick a yam engine into a suzuki frame. :lol: i'll be banished from the site.
Know John from ACS quite well, he helped me at the AutoJumble in Newark last Sunday. Initially I did ask Minxy if I could detail the Katanaha build on OSS but it was suggested it wouldn't be appropriate which is why it ended up on Phil's OSP site.
I'll get banished. :lol:
I even suggested a section for your other projects/bikes,as a lot of folk have more than one bike,but the idea was declined. But FBJ seems like a nice chap. :biggrin:
The post man delivered a big box today which I think must contain your Katana bodywork? :biggrin: I havent opened it yet. :biggrin: We'll get it looking lovely. :biggrin:
Superb Dixie, will send the decals up tomorrow, cheers man :good2:
Im off to buy the paint on Monday,so progress soon. :good2:
Quote from: dixiethedog on December 08, 2012, 11:43:12 AM
Im off to buy the paint on Monday,so progress soon. :good2:
Cheers Brett, £1800's a little rich for me though bud :flag_of_truce:
I'll be making up a billet outrigger bearing plate for the final drive shaft so the original sproket cover won't be used. I thought I'd tidy up the oilfilter housing.
(http://i214.photobucket.com/albums/cc122/cabletietom/Oilfilterhousing.jpg)
Linished to look like brushed aluminium but I think I'll polish it out.
(http://i214.photobucket.com/albums/cc122/cabletietom/Oilfilterhousing2.jpg)
Then brought the lot back home.
(http://i214.photobucket.com/albums/cc122/cabletietom/Katpickup.jpg)
A good day. and Forest won 2-0.
(http://i214.photobucket.com/albums/cc122/cabletietom/20121208_151028.jpg)
:biggrin: You must have been talking to FBM. :lol: 1800 a bit steep. :lol:
How are you doing your outrigger bearing support plate?? I did one a a few years back for my GSX1260EFE (gs1150e),but Im re-doing it,as the design was rubbish. It worked ok,but was untidy.
Im in the start process of a rebuild of the bike,so its a job on my list to do.
Id love to be able to make nice stuff like this,but i dont think ive the skill's yet.
(http://)
(http://i596.photobucket.com/albums/tt50/lindarobjones/project%20stuff/29092010191_001.jpg)
I spotted this a long time ago online,but im not sure where? Its an aftermarket cover thing for an FJ. Nice. But not an outrigger.
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/project%20stuff/Bq7OBQCGkKGrHqMH-DEEu8jultZBLgGYLnw_12.jpg)
Back to my old cover.
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/gpz750/100_0877-1.jpg)
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/gpz750/100_0879-1.jpg)
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/gpz750/100_0880-1.jpg)
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/gpz750/100_0876-1.jpg)
Morning Brett, yes spotted the conversation on 'turbo bike' :good2:. The plate will be along the same lines as yours. I'm just supplying the measurements and a chap called Sam up near Market Weighton/Poklington way will hopefully CNC me something up. Dave's sorting it as part of the payment for the lathe. He'll be doing the pickup cover and the small cover on the othe side of the crank as well. His stuff is always the dogs so I'm very much leaving it up to him.
As threatened a while ago (I mean promised! :diablo: ) here's a little clutch porn for you...
(http://fjowners.com/gallery/4/171_13_12_12_1_06_11_1.jpeg)
(http://fjowners.com/gallery/4/171_13_12_12_1_06_11_0.jpeg)
(http://fjowners.com/gallery/4/171_13_12_12_1_06_11_2.jpeg)
(http://fjowners.com/gallery/4/171_13_12_12_1_06_13_3.jpeg)
Quote from: fj1289 on December 13, 2012, 01:13:44 PM
Clutch Porn
(http://fjowners.com/gallery/4/171_13_12_12_1_06_13_3.jpeg)
Now that really is something to aspire to, beautiful dude, very impressed.
Definitely not my work! Wheel spacers are about the most difficult things I've made on my little lathe that I've actually used in anger.
From haysmachineworks.com. Tim was willing to do a one-off for the FJ. These are amazing clutches - an engine driven clutch capable of being used in multiple modes. I'm using it as a multi stage clutch.
Wow,thats some impressive workmanship there. Now pass me my rotary table,indexing head and some big lumps of billet....I wish! Ive got the gear,but ive no idea.
Thinking about it,with your bike (Tom) and FJ1289's bike,if I could have my fantasy FJ,it would be your turbo engine in FJ1289's frame. That would probably be an ultimate play toy for me. If I had to have my ultimate erm..Suzuki,your bike would be top of the list too. Although your engine in my efe would be cool. :good2:
Ive just arranged to sell an FJ12 that i have in storage,maybe i should keep hold of it? :good2:
Started to get the clutch cover together, Yantosh McYantosh turned up the Plexiglas clamp with O-ring, fits perfectly into the cover.
(http://i214.photobucket.com/albums/cc122/cabletietom/Windowedclutchcover2_zps68e8233d.jpg)
Like a glove.
(http://i214.photobucket.com/albums/cc122/cabletietom/Windowedclutchcover3_zps0f681f40.jpg)
Tomorrow I'll engrave the Glas, chop out the unnecessary bits from the inside of the cover and weld the rings into the cover.
(http://i214.photobucket.com/albums/cc122/cabletietom/Windowedclutchcover1_zpsfacf404b.jpg)
love this build.
the clutch is amazing and why not show it off with a cover!!
i want one for mine!!
very impressed... keep up the good work!
Tom - might consider welding a spacer ring to make room for the lockup while you're at it. Much better solution than a cover spacer that requires two gaskets each time you go into the clutch ....
Quote from: fj1289 on December 18, 2012, 11:02:00 PM
Tom - might consider welding a spacer ring to make room for the lockup while you're at it. Much better solution than a cover spacer that requires two gaskets each time you go into the clutch ....
The only problem with that is the clutch hub doesn't run central to the circular cut-out on the cover, by about an inch. The Plexiglas cover has an O ring so it will perform like a quick access cover for clutch adjustment and set up. I shouldn't have to remove the whole cover until the first motor strip down.
I did consider this :dash2:
Sticking it all together. Bolted to a piece of 20mm to prevent warpage.
(http://i214.photobucket.com/albums/cc122/cabletietom/windowclutchBFTFBM2_zps988806fd.jpg)
Preheat.
(http://i214.photobucket.com/albums/cc122/cabletietom/windowclutchBFTFBM4_zps9e58a21e.jpg)
Took a couple of goes to suss the heat required, old ally and all that.
(http://i214.photobucket.com/albums/cc122/cabletietom/windowclutchBFTFBM5_zpsc6fa5083.jpg)
I need to tidy up the inside a bit.
(http://i214.photobucket.com/albums/cc122/cabletietom/windowclutchBFTFBM10_zps4d58d56a.jpg)
Will engrave the Glas tomorrow if I get a minute at work.
(http://i214.photobucket.com/albums/cc122/cabletietom/WINDOWCLUTCHCOVERbftfbm_zps111c6302.jpg)
Hope you like :drinks:
Done.
(http://i214.photobucket.com/albums/cc122/cabletietom/clutchwindowoldskool2_zps32b9c0c9.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/clutchwindowoldskool1_zps075ca73b.jpg)
Happy with that :drinks:
Very cool, nice job!! Could be a job in that for you!!
Greg
Nice. If I had a nickel for every Yosh part I've used over the past 35 years........ :good:
Havoc,
Great project you have there, mate. Your engineering and fabrication skills are outstanding.
There was only one photo that showed it, but the turbo cold side outlet pipes under and behind the motor up to the plenum? Obviously no room for an intercooler. But cooling the inlet charge is critical to increased horsepower and preventing detonation. I have used water/methanol injection on a supercharged landspeed bike, and it really can be considered a 'chemical intercooler'. Inlet temperatures lowered from 200+ degF to near 100 degF. And the methanol is certainly an octane enhancement. Side benefit is that your combustion chamber will be clean as a whistle.
You mention nitrous, but have not yet shown how you intend to plumb it up. Wet or dry? I like wet because it is more idiot proof. Nitrous Express Piranha nozzles, drilled and tapped into the heads or inlet manifolds would be clean and simple. Tee-off from your fuel pump to a low pressure regulator, add a few solenoids, nitrous bottle, a button, and Bob's Your Uncle.
Again, nice work. I look forward to seeing more.
Quote from: derbybrit1 on December 23, 2012, 12:09:01 AM
Havoc,
Great project you have there, mate. Your engineering and fabrication skills are outstanding.
There was only one photo that showed it, but the turbo cold side outlet pipes under and behind the motor up to the plenum? Obviously no room for an intercooler. But cooling the inlet charge is critical to increased horsepower and preventing detonation. I have used water/methanol injection on a supercharged landspeed bike, and it really can be considered a 'chemical intercooler'. Inlet temperatures lowered from 200+ degF to near 100 degF. And the methanol is certainly an octane enhancement. Side benefit is that your combustion chamber will be clean as a whistle.
You mention nitrous, but have not yet shown how you intend to plumb it up. Wet or dry? I like wet because it is more idiot proof. Nitrous Express Piranha nozzles, drilled and tapped into the heads or inlet manifolds would be clean and simple. Tee-off from your fuel pump to a low pressure regulator, add a few solenoids, nitrous bottle, a button, and Bob's Your Uncle.
Again, nice work. I look forward to seeing more.
Enough nitrous does the same thing. :yes: I ran adapter plates for the nozzles but I do not think they are available anymore.
Quote from: JMR on December 23, 2012, 08:16:08 AM
Enough nitrous does the same thing. :yes: I ran adapter plates for the nozzles but I do not think they are available anymore.
If you refer to the APE parts, you are correct, they're out of stock and not making more. They were really nothing special though, it'd be quite easy to make your own, which will help you clear the starter if you use braided lines.
Cheers for the comments gents.
Quote from: derbybrit1 on December 23, 2012, 12:09:01 AM
There was only one photo that showed it, but the turbo cold side outlet pipes under and behind the motor up to the plenum? Obviously no room for an intercooler. But cooling the inlet charge is critical to increased horsepower and preventing detonation. I have used water/methanol injection on a supercharged landspeed bike, and it really can be considered a 'chemical intercooler'. Inlet temperatures lowered from 200+ degF to near 100 degF. And the methanol is certainly an octane enhancement. Side benefit is that your combustion chamber will be clean as a whistle.
This first build will be relatively low power @ low boost. Just need to get it on the road for now, say 220-230bhp. Bunch of us have an aircooled turbo road trip planned for easter, any of us that doesn't run a 9 has to buy the tea. Will be using a blend of C16 and Super Unleaded to keep the cost down a little, also CR is around 8.5:1 so detonation shouldn't be an issue. The next incarnation after we got this silly bet out the way will be more of everything. A larger Ball Bearing turbo with Water/Meth injection. Our main man has plenty of experience with this having run Outlaw, ProMod etc. The Nitrous system is all that remains of my GSXR1340K from th video in the first post. I did run the APE spacer plates for the foggers on the Suzi but there is plenty of space on the underside of the inlets on the head to drill and tap. The system is a wet 'NOS', was running 32/34 Gas/Fuel with 100% C16 achieving about an extra 100bhp dependant on weather but will be starting with much smaller jets on the FJ motor. Both a boost controller and a progrssive Nitrous controller are waiting in the shed for 'phase 2' :good:
Quote from: andyb on December 23, 2012, 10:53:30 AM
Quote from: JMR on December 23, 2012, 08:16:08 AM
Enough nitrous does the same thing. :yes: I ran adapter plates for the nozzles but I do not think they are available anymore.
If you refer to the APE parts, you are correct, they're out of stock and not making more. They were really nothing special though, it'd be quite easy to make your own, which will help you clear the starter if you use braided lines.
I agree. I ended up moving the nozzle locations too.
Quote from: Havoc on December 20, 2012, 03:49:14 PM
Done.
(http://i214.photobucket.com/albums/cc122/cabletietom/clutchwindowoldskool2_zps32b9c0c9.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/clutchwindowoldskool1_zps075ca73b.jpg)
Happy with that :drinks:
fantastic, how much are you charging for more of these
Quote from: fj11.5 on December 24, 2012, 08:29:47 AM
Fantastic, how much are you charging for more of these
No plans to make more, barely have time after work to get my bike sorted.
Easy job for your local engineers with Yamaha having kindly supplied the removable circular middle bit though. The Plexiglas and ally cost me about £15.
Fitted..
(http://i214.photobucket.com/albums/cc122/cabletietom/windowon2_zps8032b148.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/windowon4_zpsc0a3d174.jpg)
Happy with that. Onwards and upwards, time to wire the old girl up.
And then fit your new paint,which is still under way as I type. I shall mail you regarding positioning of decals. :good2:
Quote from: dixiethedog on December 30, 2012, 01:28:58 PM
And then fit your new paint,which is still under way as I type. I shall mail you regarding positioning of decals. :good2:
WooHoo, I'll bung up some photos of original bikes with sticker positions. Forgot about the 'Sleipnir' thing though.
Happy New Year man.
:i_am_so_happy:
Awesome build thread!
Quote from: fj1289 on December 30, 2012, 04:10:41 PM
Awesome build thread!
Thanks man. Today wasn't really FJ motor related but was pretty exclusively Yamaha. Need to mount the R1 Calliper so it bites straight on the disk on the EXUP wheel mounted in a 1979 HARRIS arm with 12" slots.. :good:
1. Make plate, drawing.
(http://i214.photobucket.com/albums/cc122/cabletietom/RearCalliperHanger2_zps04f204f1.jpg)
2. Hacksaw then file..
(http://i214.photobucket.com/albums/cc122/cabletietom/RearCalliperHanger3_zps255d5643.jpg)
3. Tap it for M10 1.25 calliper bolts, I don't use stainless for these, probably urban myth but don't like the idea of searing boolts.
(http://i214.photobucket.com/albums/cc122/cabletietom/RearCalliperHanger4_zpse142eace.jpg)
4. R1 Calliper
(http://i214.photobucket.com/albums/cc122/cabletietom/RearCalliperHanger5_zps091cfac0.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/RearCalliperHanger6_zps97f27069.jpg)
5. Gonna fit here.
(http://i214.photobucket.com/albums/cc122/cabletietom/RearCalliperHanger1_zpsb1daccca.jpg)
6. Then stick it together with Blue Glue (plenty of perheat and quite an aggresive ampage with a 3mm filler rod)
(http://i214.photobucket.com/albums/cc122/cabletietom/rearcalliperhangerwelded_zps8c3e02cc.jpg)
Bobs yer uncle and no torque arm to mess up the lines.. :good2:
Nice tidy modication there Tom. :good2: Inspired by your clutch cover Im making one for Ace, from Ace of sprays bike painters. He apparently paints bikes. :lol: He's a very nice bloke too.
nice work mate, hope to find someone as skilled with a welder as you when i need my xjr swing arm mods done
Milled up to make it a bit more 'engineered' looking rather than 'agricultural'.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130111_171729_zpsf3d3df34.jpg)
Got the old mop and soap out, black snot and Panda eyes are us..
1/2 wat through.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130111_184514_zps40a97024.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130111_184543_zpsd1b3e6e6.jpg)
Got bored after an hour, that'll do.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130111_185347_zps7e4517a2.jpg)
In situ.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130111_185654_zpsa6b65874.jpg)
Happy with that.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130111_185700_zps22a904bb.jpg)
Hey Havoc,
It's really function over form, but that looks great.
CraigO
Quote from: craigo on January 11, 2013, 05:31:49 PM
Hey Havoc,
It's really function over form, but that looks great.
CraigO
It would appear I'm a tart, who'd have known.....4 weeks until fire up, the interresting bit....
Quote from: Havoc on January 11, 2013, 07:23:26 PM
.....4 weeks until fire up, the interresting bit....
That's only the beginning of the interesting bits -- as you surely know!
What did you you for gaskets and sealant for the bigblock? Copper and copper coat spray? I tried using hylomer, but I'm getting leakage at the base gasket (and maybe at the head from the cam chain tunnel)
Quote from: fj1289 on January 11, 2013, 09:08:51 PM
Quote from: Havoc on January 11, 2013, 07:23:26 PM
.....4 weeks until fire up, the interresting bit....
That's only the beginning of the interesting bits -- as you surely know!
What did you you for gaskets and sealant for the bigblock? Copper and copper coat spray? I tried using hylomer, but I'm getting leakage at the base gasket (and maybe at the head from the cam chain tunnel)
Gasgacinch works too.
JMR - do you prefer gasgacinch on copper gaskets?
Any thoughts on improving crankcase breathing on large (or boosted- feeble attempt to keep this somewhat on topic) FJ?
Quote from: fj1289 on January 11, 2013, 09:08:51 PM
What did you you for gaskets and sealant for the bigblock? Copper and copper coat spray? I tried using hylomer, but I'm getting leakage at the base gasket (and maybe at the head from the cam chain tunnel)
I used the Hylomar spray. A mate works at Rolls Royce and he tells me that is what they use, if it's good enough for them.. :good2:
However I haven't started the motor yet so can't comment on its integrity yet.
Randy told me about spray Hylomer too - but said the spray form wasn't available anymore (maybe a regional issue?) - and the brush on form doesn't work as well. If I remember correctly, think I used a brush on version when I assembled it. Plan to pull it down this spring ...
Still available in UK
Quote from: fj1289 on January 13, 2013, 10:56:10 AM
JMR - do you prefer gasgacinch on copper gaskets?
Any thoughts on improving crankcase breathing on large (or boosted- feeble attempt to keep this somewhat on topic) FJ?
I personally use Copper Kote on the head gaskets and spray Hylomar on the base gaskets. I vintage roadracer I do headwork for uses Gasgacinch (on the copper head gasket) and really likes it. I have used Gasgacinch on SOHC cb750's after eliminating the base gasket. It has worked well.
Personally I like and use use MLS gaskets/Viton coated steel base gaskets and can get them for even vintage Honda 550's and 750's up to 72mm bore (original was 62mm). The copper gaskets seal well against cylinder pressure but do not seal against oil very well.
Not posted in a couple of weeks, not really FJ stuff fabrication non the less. Wanted to make a tail light/numbr plate bracket out of the rest of the 10mm ally I had. Had an idea in my head but didn't fancy the hack-sawing so I went over to Dave's to borrow his bandsaw. Bits cut out.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130223_160343_zpsdcc1b899.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130223_160349_zpse5cf76ee.jpg)
I was going to bolt the lot together with hidden little cap heads, Mr. Dunlop suggested he stick it together so..
(http://i214.photobucket.com/albums/cc122/cabletietom/20130223_164450_zps39667bc1.jpg)
Needs tidying up a little and a mirror polish (tomorrow) but well happy. It'll look a lot less agricultural after a couple of hours on the mop.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130223_193734_zpsdd21407c.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130223_193801_zps738ade26.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130223_193834_zps0876a909.jpg)
The camera makes it look a little twisted but it isn't.
We are all a little twisted, even if we deny it... Looks good.
Polished up a bit but I got bored and went down the pub.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130226_181647_zps579e1830.jpg)
Going to be running the old girl at the Land Speed Record do down at Pendine Sands in Wales in June, need a deadline to focus.....
Quote from: Havoc on February 28, 2013, 02:44:09 PM
Polished up a bit but I got bored and went down the pub.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130226_181647_zps579e1830.jpg)
Going to be running the old girl at the Land Speed Record do down at Pendine Sands in Wales in June, need a deadline to focus.....
That's why I end up bead blasting a lot of aluminum parts
Picked up the paint work from Dixiedog this morning, nice to meet you man :drinks:
(http://i214.photobucket.com/albums/cc122/cabletietom/20130302_132953_zps867f2462.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130302_133006_zps3ad3f9e1.jpg)
Thanks man :yahoo:
SuperKat!!!
Wow, what a bike!!! :good: Sure came together nicely.
CraigO
Looking great! That build is so clean bet it will fool a lot of people - especially the ones that grew up on water cooled bikes
Quote from: fj1289 on March 02, 2013, 01:42:18 PM
Looking great! That build is so clean bet it will fool a lot of people - especially the ones that grew up on water cooled bikes
Praise indeed, coming form you guys, means alot. I thank you. I've posted on a few Suzuki areas and NO-ONE has questioned the heart of the beast, :good2: I love this engine.
bloody awesome kat mate, best ive seen ,,
Quote from: Havoc on March 02, 2013, 09:04:34 AM
Picked up the paint work from Dixiedog this morning, nice to meet you man :drinks:
(http://i214.photobucket.com/albums/cc122/cabletietom/20130302_132953_zps867f2462.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130302_133006_zps3ad3f9e1.jpg)
Thanks man :yahoo:
Hi Tom,the bike looks great!
It was a pleasure to meet you for what was only a short time. Thank you for bring my turbo kit too!
I had had a couple of problems at the last minute with decals on the panels,where the ink had ran and stained the clearcoat. :dash1:
This had only been noticed last Thursday late afternoon,and I was giving the panels back on the saturday morning!
Six PM start(Thursday),and rubbed tank and bits back down,and a new respray. It was lets say a long shift! So,for me the outcome was the paint wasnt to the standard I would have liked.
Ive promised Tom a new paint job absolutely free of charge the next time the bike comes off the road,even if its next winter.
Ive my reputation to try to protect. :good2:
In the mean time Tom enjoy the bike,and I'll see you at Pendine sands for our own speedweek!!
The tea's and coffee's will be on me!
Now let me see,has anybody fitted a gsxr11 turbo engine into an FJ1200?........... :lol:
Quote from: dixiethedog on March 04, 2013, 12:24:10 PM
Now let me see,has anybody fitted a gsxr11 turbo engine into an FJ1200?........... :lol:
The lump is tiny in comparision, might be able to get two in there :diablo:
Wiring up the ECU.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130328_203613_zpse67fd66f.jpg)
First I had to make up the 35 pin block connector. Wiring diagram nice and clear.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130328_205848_zps61cc7b08.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130328_211842_zps76590949.jpg)
Making up the block pins.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130329_204118_zpsee4e5625.jpg)
Slowly, slowly.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130402_140817_zps31d79a50.jpg)
Buffalo solder, dreadlock wiring...
(http://i214.photobucket.com/albums/cc122/cabletietom/20130402_182713_zps4e4f3fab.jpg)
Wires pulled through a waterproof seal, the fat wire is the shielded wire carrying the inducted mA signal from the crank.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130402_203351_zps81799e13.jpg)
Getting there.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130402_205309_zps87c8c6ce.jpg)
All done.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130402_211348_zps4cb4415d.jpg)
Now I need to make the loom for all the boring stuff like lights, horn, clocks etc...
Great job sorting out the spaghetti...
CraigO
I think I would have put the wires thru the seal as I was wiring the connector... Looks like it was a bit of a PITA. Can't wait to see the video of it running. :drinks:
Boooost gauge where the ignition used to be. :good2:
(http://i214.photobucket.com/albums/cc122/cabletietom/20130502_193641_zps4bb28039.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130502_193641_zps4bb28039.jpg.html)
Where did the throttle bodies come from?
Evening man. They are 2009 XJR1300 with secondary butterflies removed, air-to-exhaust port emissions rubbish removed, injectors replaced with 680cc DEKA items. I may replace them with something with a larger bore or go Meth/water injection to in the future if I have to run too higher boost to force mixture through and inducing detonation.
What do you have left to do?
I have to machine up an outrigger bearing/clutch slave housing, an engine cover to house the 36-1 trigger wheel and pickup (going to take some work to make it look less ugly, first one I made was very agricultural), finish the wiring, rebuild the clocks so they will read over 200mph (just in case) then set the old girl up on the DYNO. Unfortunately I'm getting very little time to work on it at the moment, it's exam time at work so I'm in 12 hours a day and to tired to get up the shed in the evening. Back on it in a few weeks, hopefully ready in 6-8 weeks...
If not, I get 6 weeks off over the summer so it'll come together quickly then, already at least 2 years passed the original deadline :drinks:
Didn't like the lines of the head cooler feed line. Cut through too many other lines and looked 'tight'
(http://i214.photobucket.com/albums/cc122/cabletietom/20130302_133006_zps3ad3f9e1.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130302_133006_zps3ad3f9e1.jpg.html)
I struggled to get the feed to follow the frame lines so I made a longer one. Looks better I think.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130511_163831_zps9574cee7.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130511_163831_zps9574cee7.jpg.html)
Should finish the majority of the wiring this weekend.
If she suddenly goes missing, and all that's left is a plastic katana model, your bikes in my shed :biggrin:,, not that I like kats or anything mate :good2:
I can't wait until you get this thing on a dyno.
The new line looks much better :yes:
New line looks better. I think it's one of those things that nobody notices until you point it out though. Now that I've seen it, it can't be unseen.
Keep up the good work.
Fitted the fuel pressure gauge this afternoon to have a break from the wiring. Had to make up an adaptor to take it from M14 through a 90 degree bend to bsp on the gauge its self.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130528_171034_zps0ff03744.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130528_171034_zps0ff03744.jpg.html)
Back to the wiring :wacko3:
So me being new to the site and not having looked at everything on the forum I found this tread and OMG. I am a huge car guy but this build makes me want to sell one of my cars and build my FJ up now. This is the sickest motor. I am not sure what all to say really but very nice work.
Thank you.
Many moons ago when we made the headers we failed to spot the position of the positive pressure feed on the waste gate. Had resigned my self to blocking the old hole and drilling and tapping a new one. Decided a bit of work with the old hacksaw, grinder and file might do the job, the same as we did with the exhaust flanges. Used a hole cutter to make the big hole then set about with the saw and grinder.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_143917_zps84b23773.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_143917_zps84b23773.jpg.html)
Very pleased.
Was still too close
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_150431_zps755ef085.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_150431_zps755ef085.jpg.html)
There was a couple of mm to be taken out of the brass fitting.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_150815_zps25ada48a.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_150815_zps25ada48a.jpg.html)
Then linished on me file
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_151409_zpscc5853fc.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_151409_zpscc5853fc.jpg.html)
Loads of room
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_151529_zps629123c7.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_151529_zps629123c7.jpg.html)
Lambda
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_154117_zps596efc75.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_154117_zps596efc75.jpg.html)
Brain to fit where the coils used to sit.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_154129_zpsffaaa14d.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_154129_zpsffaaa14d.jpg.html)
Going to adapt the old FJ pick up, I think 1 of the old ones will do the job.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_152635_zps95666482.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_152635_zps95666482.jpg.html)
Also made up the fuel tap.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130531_161149_zps95bf16cb.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130531_161149_zps95bf16cb.jpg.html)
And yes it will need clamps
Where did you learn how to build a bike like this? This is truly amazing. Just out of curiousity, how much do you think you could sell this bike for? (You shouldn't, I'm just curious if there is a market for buying bikes pre-made like this; this is the kind of 'custom' that would actually be interesting.)
Hi man. I doubt it would be cost effective to build this sort of thing for profit, it's too 'hand made', like people used to do in the old days. If at all possible I would prefer to make a part than buy one. There's not enough CNC, CAD parts on it to attract the sort of buyer that would spend more on a custom build than a show room bike. I guess I'm about £6500 ($8500 US?)into it on parts etc over the last 3 years, mostly in the motor and the ECU, but I've spent hundreds of hours on it.
Where did I learn? It's a 'needs must' kind of a deal, you figure it out as you go along, I'm a hobbyist, science teacher by trade, but I've been keeping piles of shite on the road since the late '70's. Started with Honda cub field bikes as a kid, Moto X, Trials (Bernie Schreiber was my hero :) ) then Jap muscle bikes in the '80's, drag racing and Harley Chops in the '90's, anything that you can stick petrol in.......
And I've still got everything to learn. Cheers for the interrest :good2:
Quote from: Havoc on May 31, 2013, 01:34:28 PM
Hi man. I doubt it would be cost effective to build this sort of thing for profit, it's too 'hand made', like people used to do in the old days. If at all possible I would prefer to make a part than buy one. There's not enough CNC, CAD parts on it to attract the sort of buyer that would spend more on a custom build than a show room bike. I guess I'm about £6500 ($8500 US?)into it on parts etc over the last 3 years, mostly in the motor and the ECU, but I've spent hundreds of hours on it.
Where did I learn? It's a 'needs must' kind of a deal, you figure it out as you go along, I'm a hobbyist, science teacher by trade, but I've been keeping piles of shite on the road since the late '70's. Started with Honda cub field bikes as a kid, Moto X, Trials (Bernie Schreiber was my hero :) ) then Jap muscle bikes in the '80's, drag racing and Harley Chops in the '90's, anything that you can stick petrol in.......
And I've still got everything to learn. Cheers for the interrest :good2:
Good friend of mine lives in Warrington. I spent some time there and hung out with a good friend of his who's name is Pete Williams. He was one of the pioneers of 2 engine Nitro Triumphs (Two Faced') in the early 60's. Here is a vid of him making an aluminum tank. Towards the end there are some clips one of which is a Hayabusa with all aluminum body work (@ 37:00). I saw him working on the upper fairing.....it is a very complicated piece but he nailed it as shown in one of the clip.
How I make an aluminium motorcycle petrol tank (gas tank) & other alloy metalwork. (http://www.youtube.com/watch?v=rw5lYMmxSB0#)
Now that is true skill, something to aspire to. Enjoyed watching that a lot, thanks man. I have a feeling I've seen it before?. Like I said, I still have everything to learn. :blush:
The man is a true craftsman. I really enjoyed watching it. Wish I had half his skill.
Thanks,
Dan
Turbo oil feed and outlet today. Mr Dunlop sorted the scavenge pump for me along time ago.
AN-4 feed
(http://i214.photobucket.com/albums/cc122/cabletietom/20130602_200539_zpsc58db683.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130602_200539_zpsc58db683.jpg.html)
Larger AN-6 outlet to pump then return to back of clutch housing. I'm going to have to get a 90 degree bend though as the straight fitting hangs too low and looks messy.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130602_200520_zps9e16187d.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130602_200520_zps9e16187d.jpg.html)
Can't wait to see this one running in anger! First "modern" turbo install I know of on an FJ engine.
Quote from: fj1289 on June 04, 2013, 02:43:11 PM
Can't wait to see this one running in anger!
Me too man, I've got to stop faffing about with silly little things and finish it. Oil outlet looks better..
(http://i214.photobucket.com/albums/cc122/cabletietom/20130604_202640_zpsb64114a0.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130604_202640_zpsb64114a0.jpg.html)
Got braided line in the post but I'd run out of AN-8 stuff. The return is going here, looks a little messy from here but there's enough width to make it OK, didn't want to weld a tube in, loads of people do that.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130604_203312_zps9b95cd20.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130604_203312_zps9b95cd20.jpg.html)
I even bought oil, plugs and filter for the old girl this week.........
What oil, filter, and plugs did you get, out of curiousity?
This motor will require a plug 1 grade cooler than stock but I'll just be using normal Plutoline 10/40 dx in it just changing rather more often than stock. Stock Oil filter.
Need an oil catch tank, some lovely ones in the TNK catalogue. Yoshiesque part if the sprocket cover. Going to make one. More precisely going to cut out the bits and ask Dave to stick them together.. Cheerios model..
(http://i214.photobucket.com/albums/cc122/cabletietom/20130628_172008_zps35b8925c.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130628_172008_zps35b8925c.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130628_174624_zpsf4cb268d.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130628_174624_zpsf4cb268d.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130628_175606_zpsf69ed222.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130628_175606_zpsf69ed222.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130628_175828_zps3e6f398a.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130628_175828_zps3e6f398a.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130628_181434_zpsbedcc932.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130628_181434_zpsbedcc932.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130628_185451_zps2c0ef49c.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130628_185451_zps2c0ef49c.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130628_192305_zps11b9d578.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130628_192305_zps11b9d578.jpg.html)
Next weekend it will be a groovy welded ally tank, night chaps :good2:
Nice work there sir. :yes:
Quote from: JMR on June 29, 2013, 05:21:40 PM
Nice work there sir. :yes:
Cheers man. Today was all about converting cardboard to metal. First mark out on 3mm ally sheet, a bit heavy but it's what I had in the shed.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130706_154635_zps38c5fad2.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130706_154635_zps38c5fad2.jpg.html)
Fold the front plate and stick the sides on.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130706_164414_zpsc5a5e5eb.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130706_164414_zpsc5a5e5eb.jpg.html)
Prep the cover, 30 year old ally was potentially going to be a problem...
(http://i214.photobucket.com/albums/cc122/cabletietom/20130706_161407_zpsf3e18e21.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130706_161407_zpsf3e18e21.jpg.html)
Shouldn't have been worried, a tiny bit of shite floated up but it welded well.
(http://i214.photobucket.com/albums/cc122/cabletietom/20130706_191528_zps89130817.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130706_191528_zps89130817.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130706_191535_zpsd0f4f66f.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130706_191535_zpsd0f4f66f.jpg.html)
And in place, a homage to 'Pops' Yoshimura. Have to make it this big though because of new regs at the local drag stip. They require a catch tank to have a volume of +1 litre..
(http://i214.photobucket.com/albums/cc122/cabletietom/20130706_191425_zps90afef56.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130706_191425_zps90afef56.jpg.html)
(http://i214.photobucket.com/albums/cc122/cabletietom/20130706_191411_zpsf1e4bdc4.jpg) (http://s214.photobucket.com/user/cabletietom/media/20130706_191411_zpsf1e4bdc4.jpg.html)
The JIC fittings will be sorted next weekend. Beer time, cheers folks :drinks:
Tom,
it's looking great. I'm stuck out on a business trip and can't work on mine right now...so any updates on yours?!
Amazing how many "little" details are left towards the end of a huge project like this! And how much time it takes to get through them
If anyone is interested - few updates on this build from the oldskoolperformance site: http://www.oldskoolperformance.com/forum/viewtopic.php?f=6&t=723&start=518 (http://www.oldskoolperformance.com/forum/viewtopic.php?f=6&t=723&start=518)
One way or another I lost my mojo with this for a couple of years. Back on it with a vengeance now. A few small jobs (instrument feeds, little bit of wiring left, tidying up some fasteners etc)) then the interesting job of tuning the old bus up. The old girl will be ready for the first meeting next season, in April. I'll up date with some photos this evening