fj1200 turbo "thug"

[backstreetheros]

got a bit carried away after recieving some new parts from randy and spent my whole evening on the bike... completed the following
extended lock stops to stop steering travel hitting all my pipework and turbo.
braced the footpegs with a tubular brace
made and mounted the oil cooler brackets to replace the small FJ oil cooler with a 15 row impreza one.
made an exhaust bracket to stiffen up my side exit and take some of the load off the exhaust studs.
cut off the pillion footpeg brackets
fitted another set of brackets for another 15 row impreza oil cooler on the rear to cool the turbo oil system.
mounted my oil pump and bracket to the bike.
fitted my ammo box to the side of the bikes and welded on brackets to hold it stiff so the battery and ignition can be fitted.
found out some nyloc nuts to hold my petrol tank on.
and made a bracket/bolt-peice to hold the rear caliper mount to the frame.

all in all an extremely productive evening!
although i can feel my forhead is burnt from tacking things in place!

had to move the bike out of its usual shed for good now as it no longer fits through a doorway with the new lock stops and ammo box.
will do the spin on filter conversion tomorrow and fit the bits i got from RPM tomorrow aswell as take a load of pictures to post
was going to tonight but the light was poor in the workshop for taking pictures.
making progress! 

[backstreetheros]

as you may be able to see the ammo box covers the kickstand making it only possible to use by getting off the bike and putting your hand under... this was crap so we bent and welded a spanner to follow the angle of the ammo box and now can be used to kick the stand out with your foot. plus it looks funny.
i'll get pictures of that up soon.
also mounted an oil temperature gauge to the frame above the tank and fitted randys tapped sender plug (had to space off my master cylinder as it touched)

the bike is now evenly weighted due to the battery counterbalancing the turbo.

i'll get some more pictures up soon of progress.

[fj11.5]

and that is how a chopper should be built , not with off the shelf parts like certain "custom builders" use, about all they custom build are tanks and gaurds, maybe exhaust systems , , what colour you going to paint this beasty, , just do the wheels and engine black and clear coat the rest as it is 

[backstreetheros]

the bike is already painted...
its a flat rust colour with gold glitter in it made to look crappy. i've just gone for the approach of not painting anything atall, not even welds.
later on i might paint it nato green with some military stencils but at the moment i'm liking the look.
it will certainly turn heads!

still a way off yet though. need another good weekend on it and shouldnt be too far off then...
still need to order my igniton!

[backstreetheros]

done a bit more on the bike recently and managed to get most of the brakes done. converted them back to individual use and linled the rears together
ordered my dyna 2000 igniton today and coils
also ordered the tank sealer which is impossible to find in the parts shops!
also ordered two mk2 spitfire switch panels for the pumps and ignition.
went to my local ish bike breakers for a starter relay and they gave me some brake pipes and bits!
will definatly need some form of kill switch.
struggling to findanother mocal 15 row oil cooler!
need to make something as a brake fluid resivoir too.
will get some more pictures up soon.
start date is approaching fast!

[backstreetheros]

[backstreetheros]

http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/66265_10151203842530827_1667265028_n.jpg]

[minitruckeratheart]

I just read this thread, nice lookin bike. cant wait to see what itll do when shes running!

[backstreetheros]

ordered a malpassi petrol king fuel pressure regulator today. would be much happier finding these parts off oyhrr vehivles but its proving that ebay is the only place for such specialist parts.
eagerly awaiting the postman now before i can continue!
i will get a video of first start attempt and a run through of the starting procedure to prime the turbo oil!
to be continued...

[backstreetheros]

not forgotten about this project... just been busy with work...
although i have been doing a bit of shopping ready for the big day.


i've got...
castrol power 1 for the bike
castrol magnatec 10w-40 for the turbo system
some cheap ass brake fluid to get the brakes filled and working
couldnt find another matching 15 row mocal oil cooler so got this 16 row one from APS. should be able to fettle it into my brackets.
PETSEAL petrol tank sealer as the tank inside isnt the cleanest.
malpassi petrol king fuel pressure regulator with boost sensitive flow
4 NGK spark plugs. (i wanted better ones but these will do just to get it started and replace at a later date.
oil filter so i can fit the spin on filter adapter.
fuel pressure guage with T peice and 8mm hose tails
two switch panels with starter buttons
8mm banjo bolt to replace the 4mm oil feed to the turbo which i dont like the look of.

got a letter from parcelforce today saying i now have to pay customs duty on my igniton because it comes from america...
thats great seeing as i've now paid £145 (232 USD) in postage alone!! this better be good

should have the ignition in a few days so will take a day off work and get some progress made!

[rktmanfj]

http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/66265_10151203842530827_1667265028_n.jpg] [url]http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/66265_10151203842530827_1667265028_n.jpg [/url]

[backstreetheros]

got a bit carried away with myself yesterday as my dyna 2000 ignition and coils came in the post...
rushed to get the bike out and fitted the ignition and coils but had no brackets for the coils so thought i'd rush at work and get a few hours in today.
after running late from work i was determined to get something done on the bike so cleared a space in the workshop and made a start...
made brackets for the coils to hang up tight under the fuel tank.
made a bracket to hold my fuel pressure regulator
fitted my two oil coolers into the brackets i previously made on the frame
welded the boost gauge bracket on the frame and mounted that.
i did the tank sealer yesterday but snapped the petrol tap off by accident so have ordered a new one. wont hurt to have new.
i finished the ignition wiring too and fitted the new spark plugs.
after i stood back for a second i thought... this thing might just fire up?!
so i put a funnel on the carb feed and tipped a bit of petrol in (bypassing the fuel pump and regulator)
tipped some oil into the turbo just to lube it up a bit
connected up my ignition switch live to the battery
pushed the choke rod, touched the starter wire on the battery...
cranks over once then fires to my amazement!! i thought awesome its ticking over!! 
then it cuts out... so choke off... fires again on the button, ticks over lovely, no strange noises
can't believe i got it all right first time! sounds like a complete animal!!
once i managed to calm myself down a bit i carried on and fitted randys spin on oil filter adapter which was easy
bike back in the shed now... once i get the oil lines finished i'll get a video and post it up. 

[backstreetheros]

following randys advice i ditched the huge oil cooler lines i previously bought...
went to my local engineering shop today and they made me up two an-6 female to male hoses for a reasonable £53.00
they are PARKER hydraulic hoses.
then i went to bredy agricentre (tractor shop) and they supplied me with two an-10 to an-6 reducers and a Male to female an-6 elbow.
all fits well on the bike. i had the return hose to the engine made extra long so i could route it well away from the exhaust pipes.
i'll try get some pictures up tomorrow.

[backstreetheros]

finally got a video uploaded.
with the plenum removed for tesing...
fj1200 turbo first start

[FJmonkey]

The beast is alive!!!! So far so good.