GSXR1100 turbo update

[JK1]

Let´s try again:
Hi all!
I´ve been here before, I had a 1100 blower/efi build, but I never finished it
But now I´m back with a turboGSXR I traded for my Yamaha/Buell bastard.

Heres the bike when I got it:


I haven´t ridden a turbo bike for a while, so at first I thought the bike was a real rocket. But then after riding two other turboGSXRs, I was certain that something was missing, like 100hp...
The bike started and ran nice but there was not enough power. I got the bike as project anyway, so after a few weeks of riding I took it apart.


The exhaust header was leaking, the other wastegate was about to drop. I decided to build a new one, to get more space to relocate the wastegate. I´m planing on using just one gate, the outlet pipe welded to the housing.
Here´s the old:

And heres the new, still unfinished.





J

[JK1]

I´m also going to change the looks of the bike , so I bought an other frame to use while trying different tails...
I had a FZ1 swing arm lying around, so I modified it to fit in the GSXR frame.



Heres some other versions I´ve tried:


 
 

[JK1]

At first I had some trouble finding a place for the waste gate. There was no room behind the front wheel:


I wanted the exhaust gases to have a best possible way out, no 90deg angles etc.
So here is what I came up with:

I´m going to use one wastegate instead of two, so I need to divide the pipe.
 
 

[JK1]

I cut two holes in the exhaust housing, first drilled a hole, then used plasma cutter.


Then I split the bend and welded a wall between the two halfs.


I heated the housing and welded the bend with tig welder.



Now I need to fit the housing back to the bike and find an exact place for the wastegate.


 

[JK1]

Here´s a few pics of the exhaust manifold, still looks like s**t. I´m going to coat it with Black Satin to fight the corrosion..


I also tried those tails again with the FZ swingarm..



J
 

[JK1]

The project is taking small steps:

I ceramic goated The exhaust header and the turbo exhaust housing with Black Satin.

I also got a new swing arm after butchering the FZ1 arm. I friend of mine machined the extensions and I welded them on.


Yet another mock up. The swingarm is loooong... too long? I´ll just have to figure out the tail 

J
 

[JK1]

Got some wire, I hope its enough


 

[JK1]

I shortened the swingarm 50mm, looks better now.

Got more parts to throw on the bike. I´m trying to get the perfect look just havent find it yet
Too wide, I dont want any double chain system:

The monoqocue looks great but ... (..it´s not mine )

 I don´t like the strip of steel below the tank, removed it already. I need to figure out what to put there.

Another new tail, unfinished:

Tubular sssa, a little longer than the Learnerbike for poofs.


I´m ready to put the turbo and the exhaust back, I just need the exhaust gaskets.

Merry Christmas!
J

 
 

Edited February 27, 2016 by JK1
edit

[JK1]

I got the welding almost finished for the current tail:


Then I looked at the picture of the earlier version:

Now I don´t know which one is better

J
 

[JK1]

I got the tail almost finished:

I´m thinking about putting the water/methanol mix inside the tail...
I also tacked the sssa torgether, to see if there´s any trouble:



The tubing is 32mm od hydraulic tubing, looks very skinny.. Well I´m going to weld more tube to it anyway..
The tail looks too long for my taste, so here is a photo shop:


J
 

[JK1]

A few more pics, now with black tank.




I think the last one goes better with the round shapes in the tank. I´m going to sell the other, any one interested?

J
 

[JK1]

Damn! My "trolley" frame came out of the closet = is not straight So I had to scrap it, and make a new one:


I also sprayed some black:



J

 

[JK1]

I´ve been doing a lots of small stuff: cam timing, fuel pressure regulator eliminator for the in-tank-pump, painting the tail and tank, figuring where to put all the stuff needed like coils, ignition switch etc.




Fuse box:


Modified pressure pipe(?):


Rear shock mount:


Electrics:


Fuel pump fitting:


Eliminated internal pressure regulator (im going to use external):


I´m having a little trouble with the cam timing. The intake cam was 120deg from TDC, now 110. But the exhaust cam was 82deg from BTC.. The factory timing marks look ok in TDC, so what am I missing here?  The first cylinder is on the starter cover side, I used the valve spring retainer as the measuring point. And got the instructions forom here:
http://forums.banditalley.net/index.php?topic=3363.0

Thanks!
J


 

[JK1]

The cam timing was successfull after I realised the degree wheel had 3 different sets of markings :|.
I mounted the water/methanol pump on the swing arm:



Also I´m finally getting the tank and tail straight:




I modified the turbo casing a little 

Now a lots of wiring to be done...

J
 

Edited July 8, 2015 by JK1
spelling..

[JK1]

I´m finally  getting somewhere with the paint. The bodyworks´s not perfect but it´s enough for me..


 
The tail is ready for a coat of clear, the tank still needs work.
Still to do:
Weld the headlight bracket, put the turn signals somewhere, seat, wiring, wiring, wiring, wi...
J
 

[JK1]

Paint ready... I still don´t know which tail I like better



J

 

[JK1]

A few more pics:



J
 

[JK1]

....



 

[JK1]

Can You spot the difference....

 

J

Edited July 8, 2015 by JK1
spelling..

[jonny1bump]

Serious amount of work.

Got to say front wheel looks scary close in some of early pictures.

The black and yellow adds to the insane mean look of bike.

Edited July 8, 2015 by jonny1bump

[busa ash]

Cracking build will be watching this , 

[BaveR]

Great work. The tank and Seat are f#ck#ng Great!!

[Guest]

great looking bike with oooodles of power Bloody marvellous 

[E10]

Will follw....always interested in other mans opinion en works... nais so far!

[BaveR]

Will follw....always interested in other mans opinion en works... nais so far!

with above