#6

[F5 Dave]

So, explain the core please?

[speedpro]

The core is going to be positioned above the throttle bodies and goes the full width of the chassis. The outlet of the turbo goes up and feeds into the bottom on the left half. It travels up to the top tank, across the top, and down the right side into the throttle bodies. I'm going to make ducts that feed air from the front of the bike to the intercooler. I'll also make a fuel tank that fits between the seat and the intercooler leaving a space for the cooling air to pass through the core. There may be louvres involved.

[speedpro]

Very nearly finished with the flanges. Just need to drill the 2 holes in the flange to bolt to the turbo, left one. The other one will probably have a bit more machined off once I figure out how it's going to fit to the bottom of the intercooler core. Inside the turbo flange is 2.5° from about 5mm in through to the start of the other flange. Then the angle changes in 5° steps to 25°(per side) where it will open to the core. I'm not holding them together very well in the photo. When I do I can't see where they join. The OD where the connecting hose will be is 36mmOD

[Grumph]

Can you do a tank like mine but smaller ? Mine was intended for BoB race length.

What about a tank cover/engine cover done in mesh over a light frame.
Feed air in via the OE fairing ducts through the frame.

[speedpro]

I'm thinking of starting to mock up a tank tomorrow. The main mount will be the standard rear tank mount. The forward mount(s) will probably end up being the top bolts for the sub-frame. I suspect it will be about 5L when finished.

The bits of tube I have made aren't going to work. I'll be able to retain the turbo bit after a change but I'll make a new 2nd part to weld to the first. A 45° elbow from Mikunioz will fit and connect to the plenum. The elbow is 34mm ID so the alloy will have a reasonable taper.

[speedpro]

Progress with duct for cooling air to the intercooler. Luckily the worst of the welding is on the inside. I'm still thinking about how to secure it at the front. There's a few options but I might leave it for a bit.

A 45° elbow arrived from Mikunioz today so I can get back to making the connection from the turbo to the intercooler. I already have the tapered pipe designed and just need to spin it up using the lathe. As usual the plenum on that side will be mocked up using old cereal boxes.

[speedpro]

Intercooler finished. Hopefully it won't be too difficult to install now that everything is welded together. I'll find out tomorrow.

[speedpro]

Intercooler fitted with the ducting, and enough room for the little pit bike tank

[speedpro]

The pit bike tank was a bit manky so I've started work on a nice alloy one. The rear curve is similar to a stock tank and it will slope forward at a similar angle. I have nearly finished the base, although I'm debating whether to mill ribs into the bottom. It'll look cool, not that you can see it, and will save a bit more weight. Kinda funny considering how heavy the bike is compared to other bikes in the class. I've made a rear mount which will bolt into the stock mount and 2 front supports from 5mm plate which will bolt into the 2 sub-frame bolts which I'll machine a flat into and then drill and tap. There was a couple of rubber grommet things which are perfect for the job.

[speedpro]

The tank base is finished apart from welding the mounts to it. I will attach the front mounts to the subframe bolts which I have shortened, drilled through with 5mm, tapped 6x1, and machined the hex off. I made new inserts for the front mounts with a 6mm centre hole plus a 20mm washer on the end. The rear mount fits in the standard tank mount on the subframe. I have the majority of the tank mocked up using cereal boxes and have a flip-up fuel filler cap which needs an alloy piece designed and machined for it to bolt to. I've figured it out but want a drawing so it's clear. I'm not going to be able to make it all in one hit.

[Grumph]

I have the majority of the tank mocked up using cereal boxes and have a flip-up fuel filler cap which needs an alloy piece designed and machined for it to bolt to. I've figured it out but want a drawing so it's clear. I'm not going to be able to make it all in one hit.

Oooh flash. Mine uses a screw cap and matching thread from a cheap cam cover at Pick-a-Part.

[speedpro]

I looked at something like that but wanted the tank vent inside the cap. Getting it from pick-a-part was a good idea. I'll have to remember that.

[speedpro]

Been chipping away at making the tank. It's way rougher than I'd like but is quite good when sitting on the bike. Very much like the original tank when cornering or hanging off. It does have a few pin holes which I'll fix tomorrow. Tested by filling with water.

[speedpro]

Only one ittle job to do. I need to reduce the steering lock. Not by a huge amount but it doesn't need all the lock that a typical road bike has which makes them easier to manoeuvre in the carpark or garage. It now has the intercooler in place and the air duct to it, and the small alloy fuel tank which holds more than needed but the size is due to other considerations.
I fired it up with everything in place and it's still sounding fine so it should be fine at HD on Sunday. Not sure about the gearing but it's currently geared for about 130k with a 13T front sprocket, and each tooth on the front adds about 10kmh so the 14 & 15T sprockets will have it covered for sure.
Cricket will be riding the MB100/FZR bucket. Hopefully it lasts a bit better than last time when the ignition failed at the end of the first practice. It's been ridden at Tokoroa a few times and gone great so should be great. As usual it sounded real sharp when I fired it up in the drive.

[Sketchy_Racer]

Nice work, I'm curious to hear the improvements from the intercooler. I suspect if you were at 100deg IAT it will be significant.

Speaking of gearing, what size rear sprocket do you run?