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Thread: #6

  1. #1201
    Join Date
    25th March 2004 - 17:22
    Bike
    RZ496/Street 765RS/GasGas/ etc etc
    Location
    Wellington. . ok the hutt
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    19,474
    Blog Entries
    2
    Then again she asked me when we were staying like almost 20 years ago why young guys like me did racing as you and Jimmy were a lot older.

    I mean, she had a point.
    I've been told. Dreaming`s free.
    Think I'll go, back to sleep.
    Everybody listen, voices in my head
    Everybody listen, do yours say, what mine says?

  2. #1202
    Join Date
    12th February 2004 - 10:29
    Bike
    bucket FZR/MB100
    Location
    Henderson, Waitakere
    Posts
    4,064
    Quote Originally Posted by F5 Dave View Post
    . . . . you and Jimmy were a lot older.
    and faster

  3. #1203
    Join Date
    12th February 2004 - 10:29
    Bike
    bucket FZR/MB100
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    Henderson, Waitakere
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    4,064
    It's a bit "busy" on the left now. I'm going to angle the airfilter up and back a bit to clear the electric water pump, for the moment. My plan is now to make a new as short as possible exhaust manifold and mount the turbo right in front of the exhaust ports. A lot more heat and energy will be retained in the exhaust gas that way.
    It will also tidy up the plumbing a whole lot. I'll get it going first with all the stuff I already have.
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  4. #1204
    Join Date
    12th February 2004 - 10:29
    Bike
    bucket FZR/MB100
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    Henderson, Waitakere
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    4,064
    Sometimes I'm not sure how to make something and start off figuring it out with a basic drawing. This is for the new turbo exhaust manifold. I'd found what size u-bend that was the closest to what I needed and of course I had the size above and size below what I wanted. I was getting my mate Kev to weld the air filter mounting flange and he mentioned that the place over the road had mandrel bends. I popped over to check it out but the guys were saying no they didn't, but . . . . . they had these other little pipes in black steel. They were OK but a bit too solid. However these little SS pieces are basically what I drew so were a bit too hard not to buy. I was considering stainless steel and these kicked that idea over the line.
    Nice little winner to end a cold wet miserable day.
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  5. #1205
    Join Date
    12th February 2004 - 10:29
    Bike
    bucket FZR/MB100
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    Henderson, Waitakere
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    4,064
    Had a productive couple of hours spinning up a couple of exhaust spigots for the new turbo manifold. I still need to sort out a few things like whether to weld the mounting flanges to the pipes or not. I'm currently leaning toward welding as it will provide another layer of support. I finally got around to removing the turbo from the bike to measure the inlet. It's way smaller than the gasket so lucky I did.
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  6. #1206
    Join Date
    12th February 2004 - 10:29
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    bucket FZR/MB100
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    Henderson, Waitakere
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    4,064
    How to assemble the pipes to the bosses and flanges.

    I'm thinking the idea is to weld the pipe direct to the boss. I'll need to make a simple jig to line the pipe up on the boss but that's easy.
    Then the flange can be slid down, the pipe oriented at the correct angle to meet up with the other pipe, and the flange then welded to the pipe. I might also weld the flange to the boss on the other side. This should make a reasonably secure structure once welded to the other pipe.
    Where the pipes come together and the turbo is mounted, the 2 pipes with an ID of 28mm will be machined with flats where they join together. Slightly more than 1/2 the diameter will need to be removed and then once welded together the end will have to be made round and hopefully have an ID matching the turbine inlet of about 24mm. A slight adjustment could be made using the flange. I don't think it's critical as the turbine housing inlet is as-cast and not particularly round. Something close would be good though.

    I 3D printed a flange so I can get a better idea of how it goes together
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  7. #1207
    Join Date
    12th February 2004 - 10:29
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    bucket FZR/MB100
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    Henderson, Waitakere
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    A bit more progress on the turbo exhaust manifold. In the end I didn't need a guide to centre the pipe on the boss. Instead I made the boss as I had drawn it with a recess that the pipe fits into. I dropped over to Kev's place last night to chat about how this was going to be assembled. In the end Kev machined the taper in the boss, 26mm-28mm, and then the recess. After tacking each pipe to a boss we then jigged it up on the bench and scribed the cut lines. If I had cut it in the mill instead of with a cutoff disc in the grinder it would have been spot on.

    The good thing is that cutting the pipe so that the 2 halves fit together leaves the exit a bit small so I'll have to cut it back till the size is correct. Giving it a quick eyeball the turbo was going to be a bit close to the front wheel but there is a couple of things I can do if required.
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  8. #1208
    Join Date
    12th February 2004 - 10:29
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    bucket FZR/MB100
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    Henderson, Waitakere
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    4,064
    Got a bit more done over the weekend. Kev gave me a piece of aluminium. In the lathe I faced off the top and bottom so they were flat and parallel and spun the exterior to clean it up so I could get a good reference off it. Drilled a 10mm hole through the middle to clamp it on the mill. It was then clamped down on the mill, clocked up to locate the centre and then offset in the X axis to the distance for the flange bolts which I then spotted. Took it over to the drill press and drilled and tapped the mounting holes. Once that was done I mounted the first flange on the alloy and mounted it in the lathe. I drilled the centre hole using a big drill and then bored it out to the desired size. I actually went up .25mm in size to get it over the pipes. The 2nd flange was simply a repeat. The good thing is that now I have the alloy boss I can easily make more flanges with good accuracy. The pipes need a bit more taken off the ends where the turbo mounts. It looks like it's OK but until there is a slight gap it's hard to tell if the pipes are under any stress. Pretty happy with how it's coming along.

    I have decided to get my own machine tools. A good friend gave me his drill mill which I have used previously a very long time ago. I'm still looking for a lathe. The mill is 3phase and I've decided to go with a rotary phase converter so a 3phase lathe is fine as well. It turns out that I could get a 240v 32amp supply to the garage. I very much doubt I'll need anything like that, but it's nice to know.
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