Danm54

V-band clamp is finished, just need to decided on a wastegate, going Tial but think I might go for the v-band option for the extra few quid.

Its a little late now but you should probably have hung it from points over the dowels, not the centre Still, I'm sure you can use that again with a bit of silicone.

Didn't purge inside no, should have done I suppose but I cleaned up any bits on the inside as I went along. I welded the outer 2 fully first then set up and fully welded the inner 2 but I left one joint on each just above the collector. I trimmed these to fit last then bolted it all to the head and welded the last joint. Tacked it in a couple of places around the tube the alternated the welding leaving it to cool between welds so it didn't get too hot. Well fitting tube doesn't seem to warp much but anything with gaps pulls in and long runs on collectors seem to warp too. I'm no expert though!

They were pretty much spot on but I was careful on the order I welded it in and didn't trim the last bits until the rest was welded. I also had them bolted to a spare head during welding. Plus they're reasonably easy to tweak a touch if needed.

Started on the wastegate, need to trim the length a little but I'll wait until the new gate is here first. Will probably get it welded to the headers first then I can finish the rest off.

Nope, the RF uses downdraft carbs that will sit at the wrong angle on the gsxr. Edit, beaten like a ginger stepchild...

Im no photography expert but the shed lighting as all wrong at this angle! Tacked it together now and need to sort out the wastegate connection.

O-rings fit a treat, not sure if the grooves were machined to fit a 42.5mm o-ring but they're a perfect fit.

Cams dialed in finally, the degree wheel had moved a touch so reset it and double checked it all once I'd finished. Intake lobe centre is 108.25 Exhaust lobe centre is 110.5 Got a few other bits bolted on but hit a problem with the plenum, the o-ring seals are made of cord and have shrunk slightly so there's now a gap. Measured up and ordered some new ones, hopefully they'll fit. Can get the headers back on though and finish them off.

Well today was build day but it didn't start until mid afternoon! Got the head on and then spent forever dialing the cams in. The spacer under the barrels threw things out a bit and it took a bit of working out to get the cam sprockets right so the adjustment range worked ok. Got the exhaust cam at 110.5 degrees which is spot on but the intake cam keeps falling 1-2 degrees out either way. Left it for tonight and I'll re-check the degree wheel and exhaust cam tomorrow then have another go at the intake cam.

Considering the bleed valve for the wastegate was wound fully in, its a possibility. Had a couple of tight intake valve clearances and the MAP sensor went down during tuning with John so the engine didn't get an easy time. Biggest problem at the minute is waiting for people to pay their bills but considering I'm only 3 weeks in and done a maximum 4 day week its looking good.

Cheers Ash, getting enough work to get by with a few days off to play as well. Monday is looking like engine rebuild day!

Its arrived earlier than expected! Can crack on and get the engine back together now.

The bigger the better right?

Got a mate to pop over and give me a hand on with the barrels, put the pistons in while they were on the bench then dropped the gudgeon pins and buttons in whilst holding the barrels up. Tricky but fairly easy with 2 pairs of hands.

Little comparison between the new and old pistons, both MTC turbo. New ones have loads more meat on them.

Used the copper base gasket I had made a couple of years ago and with a 0.18" head gasket I'll come out with 9.14:1 comp ratio and 1.77mm squish.

So progress is slow as I've just started my own company, going to be tight on cash for a bit but may get some full days on the bike whilst work comes through. So this afternoon was cc time Need to dig out the calculations from last time then see where I stand on the comp ratio.

Use a bolt of the same thread with a nut on it to tighten the plug in, worked fine on the one I done.

Mr Dunlop sent me to Universal Turbos as well, they sent a courier to collect the turbo, stripped it down and rebuilt it to suit my engine. Top service and not too expensive either.

Finished the headers, spooned one of them when I cleaned too much inside and broke through, sorted it ok but it could look nicer. Got a full sized rad in with plenty of wheel clearance so should keep it cooler now Made an adaptor up to get from the twin 38mm to the 51mm, wont go into the v-band but its good to hold it while its tacked. Got to move up yet so I've got some trimming to do

Mine used a seperate ignition amplifier which worked fine before the Microsquirt died. Not sure how they last long term but it seemed a fairly common addition.

I think fuel flow may be an issue, I'd imagine these are are designed to be used with a pump so may suffer with just gravity pressure. My 1100W wont sit at motorway (ish) speeds when the tank is running low, need to switch to reserve early. Thats with the standard twin outlet tap. Restrict that down to a single solenoid and you may have issues.

Progress today Cylinders 2 & 3 next. Barrels and pistons are with Wards waiting to be bored. Cylinder head has been checked for flatness on a CMM, its 5 microns out so I think its flat enough...

More header bits have arrived And some damn expensive pistons Stacked out with work again so these will have to wait until next week.