Turbocharging by ninja on minimum wage - Kawasaki Forum :: KawasakiWorld.com
 23Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 94 Old 05-17-2017, 06:07 PM Thread Starter
Member
 
YoWattup's Avatar
 
Join Date: May 2017
Location: Brisbane, Australia
Posts: 44
Turbocharging by ninja on minimum wage

Hi There. Long time listener, first time caller.

A short story before we begin - I bought this ZX12 purely to turbocharge. I've done a turbo conversion to my car, and after reading some threads on here about budget turbo setups, I figured, how hard could it be? \_(ツ)_/

So I got the bike cheap cause it was a streetfighter conversion - meaning it had been crashed at one point. $3400 AUD. Its got a PC3 which saves me $500 to begin with. Good score I think.

But then I lost my job. So the build got put on hold. Then I scored an apprenticeship, but its part time. So I'm veeeeeeerrrry short on funds. But when you gotta go you gotta go.... fast that is. And I gotta go fast. So I said fuck food and shelter who needs that? And I've decided to start on the build.

Here's the bike.



So I've only just started the build but heres what Ive done so far.
I contacted forum member and all round good guy Scott Davis a few months ago about turbo ZX12s and ended up grabbing an exhaust flange off him. I then got some 1 1/4 sch40 steam pipe and tacked up a manifold.




Im gonna get my buddy with a tig welder to weld it up completely. But before that I gotta get a T2 flange for my turbo! But thats next payday. Baby steps.

Ive also made an excel spreadsheet of estimated costs if anyone would like to know what I'll be PLANNING to spend. Keyword: planning. Anyone whos ever had a turbo car/bike knows its a fuckin nickel and diming money pit. But that's a problem future me can deal with.




Plan and reasoning behind the build:

I was able to score a GT2871R for cheap. Which is quite a large turbo for this application. But my thinking goes - a larger turbo at say 7psi will not heat up the charge air as much as a smaller turbo at 7psi. Add the fact that I'll be running it on E85 and in my head I should be able to get away without running an intercooler and sticking to stock internals. I'd be happy with >200hp and a 9 second pass. I'm not shooting for the moon here. Hopefully I can get it done on 7psi.

The plan is to do most of the tuning myself on the road, and at the strip. With a PC3 ignition module to control spark. Otherwise known as alpha-n tuning. Which is a terrible idea, because when the bike is accelerating under different loads, the turbo will spool at different times, but since this ECU system has no boost reference, it only calculates injector pulse width based on throttle and RPM, it WILL be overfueled or underfueled in some gears. Obviously being underfueled is less desirable, the plan is to tune the bike in a high gear, and in the lower gears, part of the rev range will be running a bit rich. I am doing this because its the cheapest way to do it.

Anyway that's all I've got for now. Fell free to tell me how stupid I am.

Stay tuned for next week when I finish the manifold!

Peace
andy1965 and turbo2112 like this.
YoWattup is offline  
Sponsored Links
Advertisement
 
post #2 of 94 Old 05-19-2017, 01:56 PM
Senior Member
 
turbo2112's Avatar
 
Join Date: Dec 2012
Location: oakville on canada
Posts: 392
Garage
looks interesting good luck with your build
turbo2112 is offline  
post #3 of 94 Old 05-19-2017, 07:23 PM
Senior Member
 
KZScott's Avatar
 
Join Date: Jan 2007
Location: Ontario, Canada
Posts: 6,243
Send a message via MSN to KZScott
a 2871 isnt that big, its a great choice for a street bike as its a high performance small frame turbo, its actually the smallest turbo we use in any kit we make.

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
KZScott is offline  
Sponsored Links
Advertisement
 
post #4 of 94 Old 06-05-2017, 05:19 AM Thread Starter
Member
 
YoWattup's Avatar
 
Join Date: May 2017
Location: Brisbane, Australia
Posts: 44
Some update/progress pics to let y'all know I'm still going with it.

I changed the design and sussed out placement of the turbo. Placing it here allows

1. the radiator to stay where it is.
2. The oil filter to stay where it is
3. The oil cooler to remain installed
4. The compressor side to face right which looks cool when I park it. (Its the little things)

However I have to remove the hose tail on the radiator that connects the hose coming from the oil cooler. It is now routed to the front of the radiator. Pics of that on the way. Sorry for bad pics. I dont have a shed I work on the grass until the sun goes down and I dont have any light. XD XD









A few thoughts:
The steam pipe is 1 and 1/4 inch schedule 40 stainless steel. I hope it is not too restrictive of a size but I would not be able to have done it any bigger.

The manifold is a log manifold design with small pipe diameter. In theory this is bad but I made it to be compact, sit high, and fit nicely behind the radiator. Hopefully I wont need a scavenge pump but it looks like I might after all.

I've decided to go with the Multi-Function hub for PC3 with boost input. This combined with the ignition control module and base PC3 should make it possible to get a decent tune. And its not too pricey. After some thought, using alpha-n tuning for a boosted motor is a little crap, even by my standards.

More pipe is in the mail! Should finish fabbing mani next week. Then to hand it to my buddy to tig weld it all up. Then comes oil routing and intake.
2fat2fly likes this.

Last edited by YoWattup; 06-05-2017 at 05:25 AM.
YoWattup is offline  
post #5 of 94 Old 06-06-2017, 04:07 PM
Senior Member
 
KZScott's Avatar
 
Join Date: Jan 2007
Location: Ontario, Canada
Posts: 6,243
Send a message via MSN to KZScott
I use 1.25 shed 10 stainless. O.D. - 1.65 (42mm) I.D. - 1.45 (37mm) your thicker wall stuff is a little smaller on the id, but should be ok for a low boost application. the t joints are quite restrictive vs a manifold that flows into a collector. it will work, just wont have as much power per pound of boost as what it could be. car guys do it on hondas etc all the time.

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
KZScott is offline  
post #6 of 94 Old 06-06-2017, 04:13 PM
Senior Member
 
KZScott's Avatar
 
Join Date: Jan 2007
Location: Ontario, Canada
Posts: 6,243
Send a message via MSN to KZScott
ps i like to press spigots into those flanges like this. they are sized for the 1.25 shed 10 and it fits the exh gaskets very well
Attached Images
File Type: jpg 19022774_10158675379580004_1591016095_o.jpg (64.9 KB, 33 views)

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos

Last edited by KZScott; 06-06-2017 at 04:15 PM.
KZScott is offline  
post #7 of 94 Old 06-08-2017, 11:52 PM Thread Starter
Member
 
YoWattup's Avatar
 
Join Date: May 2017
Location: Brisbane, Australia
Posts: 44
Interesting, Scott. After some measuring and thinkin' I was going to use 1.5 sch40 and machine the OD down to the exact size of the gaskets. I thought 1.25 would be to small because when I test fitted it it was rather loose. I'll have to check again. Thanks for your input! Super useful info as usual.
YoWattup is offline  
post #8 of 94 Old 06-10-2017, 05:49 AM
Senior Member
 
Hibs's Avatar
 
Join Date: Jan 2006
Location: El Paso, TX
Posts: 3,335
Love where this project is going so far... and working in the grass until the sun goes down, that sir is some damn fine determination and commitment! I respect that!
Hibs is offline  
post #9 of 94 Old 06-10-2017, 06:47 PM
Senior Member
 
KZScott's Avatar
 
Join Date: Jan 2007
Location: Ontario, Canada
Posts: 6,243
Send a message via MSN to KZScott
yes you have to admire the drive to get it accomplished.
my first turbo system was 1.5 in shed 10. super tight in the head and the id was was too big(shed 40 is likely better for id). ive used 1.25 shed 10 ever since. even my 500+hp dyno runs were 1.25 so it flows lots :)

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
KZScott is offline  
post #10 of 94 Old 06-25-2017, 01:23 AM Thread Starter
Member
 
YoWattup's Avatar
 
Join Date: May 2017
Location: Brisbane, Australia
Posts: 44
I've been doing some more work on the manifold. It's almost done! this has taken much longer than planned but its coming along nicely.

Pictures speak louder than words:


Here it is as of right now. Tig welded by my buddy. Just needs the spigots (correct term?) welded on.




Welded both sides. Ill go over this area with a die grinder later on to get it all smoothly ported.


This little section was a pain in the ass and took almost all day due to my lack of tools but turned out okay after I took it to my buddy's place and it was shaped with a torch and hammer and welded.




I had these machined out of 1.5 sch40 pipe. They are about half a mm smaller in diameter than the gaskets and 20mm long. My father has a lathe so no cost there


This is how they will sit.


Turbo in frame for reference


I like the K.I.S.S concept and I am trying to keep most of the work done in a 'backyard mechanic' style, with very little fancy equipment used. To prove a point; that you dont need money or equipment to do crazy sh*t to your vehicle. I kinda broke my own rules with the tig welding, oxy torch and especially the use of a lathe. But I think it would still be easy enough to get the same results using an $80 stick welder and settling for a slightly smaller sized pipe for the spigots. So no fancy tools NEEDED so far.

Next is charge piping. I'll be using steel exhaust pipe because I cant weld aluminium and dont want to use a million silicone joints.
andy1965 likes this.

Last edited by YoWattup; 06-25-2017 at 01:27 AM.
YoWattup is offline  
post #11 of 94 Old 06-27-2017, 02:56 PM
Senior Member
 
dastardly's Avatar
 
Join Date: Aug 2014
Location: australia
Posts: 1,021
Hi YoWattup seems like you are having fun with your build, after all the welding do you need to have the face plate machined or some wet and dry on glass to make sure it is nice and flat before you bolt her together, looking good and enjoying the pics keep posting, from another QLDer Craig

if anything goes wrong check the battery
no longer a rider but still an enthusiast
dastardly is offline  
post #12 of 94 Old 06-30-2017, 10:18 PM Thread Starter
Member
 
YoWattup's Avatar
 
Join Date: May 2017
Location: Brisbane, Australia
Posts: 44
Thanks dastardly. The flange itself does not need to be flat but the spigots that will be welded on do. The plan is exactly as you describe - some emery tape on a flat surface of some sort and a buttload of elbow grease. I've just tacked on the spigots today and will be getting them welded hopefully tomorrow. Expect more pics in the next 36 hours.

Sorry my replies are slow - I only get on my computer on the weekends.
YoWattup is offline  
post #13 of 94 Old 07-02-2017, 12:20 PM Thread Starter
Member
 
YoWattup's Avatar
 
Join Date: May 2017
Location: Brisbane, Australia
Posts: 44
Here are the spigots tack welded on. Gonna give welding these a go myself. Just ordered some 2.0mm stainless electrodes for my lunchbox-sized stick welder. :D



YoWattup is offline  
post #14 of 94 Old 07-02-2017, 01:06 PM
Senior Member
 
dastardly's Avatar
 
Join Date: Aug 2014
Location: australia
Posts: 1,021
you will love welding with stainless electrodes they just flow so nice they make amateur welders look like pros. Add a few more tacks before welding or the spigots will move, and wear safety glasses when you chip off the slag the slag off the stainless weld just pings off not good for the eyes, not telling you how to suck eggs just trying to add a little helpful advise from an old welder. I have been teaching my son to weld over the last year but it has been difficult as I can no longer hold the electrode holder as my Multiple Sclerosis is fuc**ng with me, he went to tafe doing a school based corse the teacher said wow you picked welding up quick you ever welded before, my son said nah so I had a word to the teacher he said I knew he had help good luck with your project can't wait for that dyno chart Craig

if anything goes wrong check the battery
no longer a rider but still an enthusiast
dastardly is offline  
post #15 of 94 Old 07-09-2017, 05:21 AM
Senior Member
 
2fat2fly's Avatar
 
Join Date: Sep 2009
Location: Ohio
Posts: 266
Looks like you're doing a fine job with what you've got to work with. Backyard ingenuity is the backbone of the modern world.


Sent from my iPhone using Tapatalk

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford
2fat2fly is offline  
Reply

  Kawasaki Forum :: KawasakiWorld.com > Kawasaki World > NOS and Turbo

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki Forum :: KawasakiWorld.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Just picked up a 1987 ninja zx600r eskimo619 ZX-6R 2 05-21-2017 05:09 PM
stop and tail light bulb holders michael phillips ZX-12R 3 05-16-2017 01:16 AM
rim swap zx12r zx12rRider ZX-12R 0 01-10-2017 02:22 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome