I only just realised theres a typo in the title of this thread. Its supposed to be "Turbocharging MY ninja on minimum wage". Oh well.
Here's my progress in chronological order since last time:
Here's how I flattened the spigot faces. This took a long time and a lot of elbow grease but it worked. 40grit emery tape. Also welded them studs into the T2 flange there.
Not pictured I also cut up some bolts and replaced the manifold studs that were in the head. The old ones were about 5mm too short.
Next I got this oil cooler coolant return hose mounted on the front. It used to be on the rear of the radiator but it was in the way of the turbo. Since it was aluminium I could not do this myself so I had it sent away. So far the only thing I've NEEDED someone else to do. It was free for me but it wouldnt cost any more than $50 for labor.
The radiator ended up hitting the turbo so it will have to sit about 10mm further forward than stock. I'm a little annoyed at that. The mud guard was hitting The radiator but I have trimmed the mudguard and all is well. Didn't get a pic of that for some reason.
I finally took the throttle bodies off which wasn't as hard as I thought it would be but was still a bit of a pain. I was super-duper stoked when I saw this:
Why am I happy about that? That right there is what I would call a "capped" style injector. It means there is a plate welded over the tip of the injector which reduces the flow. Remove that plate and you've got a higher flowing injector with factory fit. Here's a better pic:
I had some other unknown injectors lying around and I decided to decap them. Here's what it looks like after decapping, before and after:
Basically you gently grind away the plate until it peels off, uncovering the bare pintle beneath. You dont want to touch the pintle with your grinder.
This technique is popular in the Subaru and Chevy LS worlds. Here's an example of an injector you could not do this to, this is out of my car:
So I will do that to the ZX12 injectors and of course get them flow tested.
Lastly, after trimming the rear of the mudguard, I got to work trimming the front because I always hated how ugly the 02 ZX12 guard looked. There's just too much meat. Grinder time.
After, sanded and ready for primer:
I think it looks a lot better than the Goldwing style it was before.
Next big thing is oil feed and return. I've ordered some fittings from ebay and while I wait for them I might paint the manifold, turbine housing and intake piping. Black for stealth. Gotta figure out a fuel pressure regulator too.
If any turbo/nitrous guys are reading this I have a few questions: What are you doing with the PCV system? Just routing it from the valve cover through a filter and to atmosphere? Secondly, what's the word on fuel pumps? Whats everybody running? Is it just a standard car-sized in tank pump? Will a Walbro 255 work?