turbo build 2023

[Breadman]

We all like pictures. But before that, a quick back story.

 

A chance came up to buy a load of parts and and a bit of a project.

So I have now ended up with a 1200 bandit engine. Totally rebuilt by me and a couple of friends.

Edited July 15, 2023 by Breadman

[Breadman]

[Breadman]

EFI with modifications to use alternative injectors

[Breadman]

GSXR 750 L frame with thug yokes (maker unknown)

[Breadman]

[Breadman]

First big problem was the ARP rod bolts decided to contact the oil channel in the lower crankcase.

I decided not to grind these down and promptly set about grinding into the oil channel. Once clearance was obtained, I then inserted a copper pipe in there and made sure it was going to do the job of getting the oil up to the gearbox. Time will tell if this was a good idea

Edited July 15, 2023 by Breadman

[Breadman]

[Breadman]

[Breadman]

After putting the crankcases together it was time to move onto gapping the pistons which I have never done.

So I bought a ring grinder from Amazon, got the rings done , and then sent the item back to Amazon and got a refund.

[Breadman]

[Breadman]

The cylinder head had been worked on by a local engine builder when I got it. The work looks fantastic.

Edited July 26, 2023 by Breadman

[Breadman]

[Breadman]

[Breadman]

I skimmed the head and got the valve seats re-cut and was very happy to get this bolted down and in place using APE studs and nuts and genuine gasket.

[Breadman]

[Breadman]

Standard cams fitted and valve clearances done, it was time to get the engine crane out and fit it in the frame.

Attempt number 1 was made without the cam cover fitted but then I couldn't fit the cam cover on.

Attempt number 2 was more successful. But I did have to grind a small section of the frame...about 5mm... and then the cam cover slid into place. Threebond sealant everywhere and much poking and prodding to fit the rubber gasket and finally secure the cam cover.

 

Edited July 15, 2023 by Breadman

[Breadman]

[Breadman]

So to get from this stage to the engine in has taken me 5 months.

[Breadman]

I had to find some better plastics which a friend got me at an Autojumble and at all the lugs are  in place.

The tank was originally modified to fit a Bandit frame but after some welding, I have managed to get all the fuel line fittings welded. The tank brackets still need to be modified.

[Breadman]

Moving onto the turbo which came from a Volvo. The header pipes were made already. I have welded the wastegate flapper up, thrown away the actuator and am in the process of fitting a Tial wastegate.

Edited July 16, 2023 by Breadman

[Breadman]

Have now fitted an FBM clutch access cover. Stuck the fuel pump and fuel reg on a plate, ready for the fuel lines to be plumbed in.

[Breadman]

I was lucky enough to get a Megasquirt ECU wen I took on this project and it came with various sensors and a wiring diagram supplied by Arttu who is on this site.

Once again, I am in unknown territory as I hate wiring but I have come this far and I am trying to get my head around what I have to do.

 

[Breadman]

Facet pump has been crudely bolted in place and a small catch tank from the turbo oil drain has been fitted. The tank will have to be redone as I'm not too happy with it.

 

 

Edited July 15, 2023 by Breadman

[Breadman]

Crank trigger wheel supplied with the ECU

[Breadman]

More to follow. soon.