Gen 2: 2006-2007 New Turbo Project - Kawasaki ZX-10R.net
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post #1 of 197 Old 01-05-2014, 08:13 PM Thread Starter
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New Turbo Project

...aka: The Baller on a Budget Build

Well, this project is starting to roll, so I'll post up progress as I go along. The short term goal is to have a 10psi, pump gas, water/meth injected set-up on a stock motor until something breaks, and then put in the mildly built (pistons, rods, clutch, valve springs/retainers) spare motor and run 16ish psi... again on pump gas and water/meth injection.

Being that I'm a broke-ass, I'm using my old supercharged bike as a base platform. It already has the fuel system and electronics to support 10psi... all I really have to do is modify the intake plenum, build a proper turbo exhaust, and clean up the look of the bike... I'll actually have my friend/airbrush artist paint the bike this time around. For the time being I do plan on taking and inch or two out of the ride height and going to a single side mount/traditional exhaust pipe....... no plans to stretch it or put an arm on it as of yet. Pictures to follow.... :)

Attack life... it's going to kill you anyway.

Last edited by SpazOnaZX; 01-05-2014 at 08:39 PM.
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post #2 of 197 Old 01-05-2014, 08:13 PM Thread Starter
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Oil filter relocation

After looking at my turbo, I decided that the stock oil filter placement wasn't going to work. Even if I wasn't a cheap ass, no one really makes a proper relocation kit for the 2nd gen.... so we fired up the machines and made a remote kit out of the stock pieces. Using good AN fittings, Aeroquip heavy duty push-loc hose, and using a spare housing the whole thing ended up being less than 100 bucks to modify. :)
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Attack life... it's going to kill you anyway.

Last edited by SpazOnaZX; 01-05-2014 at 08:20 PM.
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post #3 of 197 Old 01-05-2014, 08:31 PM Thread Starter
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Turbo placement

...I just happened to have a Disco Potato with a .86 A/R turbine housing laying around, so it fit nicely with the HP & budget requirements of the build. I'm using schedule 40 stainless to build a manifold this time, and using individual ports/runners instead of the one piece flange I tried on a different bike. The one piece flange was just a PITA to work around, heavy, and had sealing issues on the other bike. The flanges were cut on a CNC plasma and hand finished to fit the pipes nice 'n tight. Here are some picks of the snail where it's going to live in relation to the engine. With the very short runners and thermal barrier coating, I'm shooting for having full boost threshold at or below 5.5K rpm. :) Another great benefit is the fact that the turbo is high enough to not need a scavenge pump for the oil return, even with the radiator in the stock position & size.
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Attack life... it's going to kill you anyway.
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post #4 of 197 Old 01-05-2014, 11:24 PM
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post #5 of 197 Old 01-06-2014, 01:30 AM
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Are you going to run progressive controller with the meth kit, that could probably help a lot with fueling since you're running power commander.
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post #6 of 197 Old 01-06-2014, 02:41 AM
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Oh damn this should be awesome. Whatre you doing with the rotrex?

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post #7 of 197 Old 01-06-2014, 08:48 AM Thread Starter
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Quote:
Originally Posted by thundercoupe9 View Post
Are you going to run progressive controller with the meth kit, that could probably help a lot with fueling since you're running power commander.
Nope, just going to run it on a Hobbs switch @ about 5psi. Progressive controllers are junk when you're trying to use them to pulse a motor. I'm actually going to change to these guy's set-up soon: http://www.rbracing-rsr.com/waterinjection.html . Seriously, read that page and learn some really, really good stuff about AI.

I'd like to ditch the power commander at some point and switch to better management. The Microsquirt is a little over my head at this point, though I'm sure I could figure it out if I had a good starting point. Really, I'm just trying to keep cost down as much as I can, and the powercommander stuff works, even if it is clunky. I may retrofit the PCV, but having to buy ANOTHER ignition module is holding me back from doing that. At that much I could almost get and FI/C.

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Originally Posted by -Op-
Oh damn this should be awesome. Whatre you doing with the rotrex?
It's probably going to sit in my garage until something comes along that seems like a bad idea to put it on. Maybe a quad or a cart or something.... who knows. :) I'd sell it all relatively cheap, but I doubt anyone would really buy it.

Attack life... it's going to kill you anyway.

Last edited by SpazOnaZX; 01-06-2014 at 08:51 AM.
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post #8 of 197 Old 01-06-2014, 09:49 AM
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I wanted to use the rb racing for my meth kit to but at the time they had not produced their up dated setup yet n wernt selling r they selling the kits now or you jus know how to get hands on same parts they would use? Wut type of power u gonna get at 5 psi with turbo



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post #9 of 197 Old 01-06-2014, 09:54 AM
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Quote:
Originally Posted by SpazOnaZX View Post
Nope, just going to run it on a Hobbs switch @ about 5psi. Progressive controllers are junk when you're trying to use them to pulse a motor. I'm actually going to change to these guy's set-up soon: http://www.rbracing-rsr.com/waterinjection.html . Seriously, read that page and learn some really, really good stuff about AI.

I'd like to ditch the power commander at some point and switch to better management. The Microsquirt is a little over my head at this point, though I'm sure I could figure it out if I had a good starting point. Really, I'm just trying to keep cost down as much as I can, and the powercommander stuff works, even if it is clunky. I may retrofit the PCV, but having to buy ANOTHER ignition module is holding me back from doing that. At that much I could almost get and FI/C.


It's probably going to sit in my garage until something comes along that seems like a bad idea to put it on. Maybe a quad or a cart or something.... who knows. :) I'd sell it all relatively cheap, but I doubt anyone would really buy it.
I can put a plug and play microsquirt together, I just have to order ecu plugs and vw ignition module.

For some reason running meth kit progressively sounded like a very good idea to me, it could handle some of the extra fueling under boost.
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post #10 of 197 Old 01-06-2014, 11:49 AM Thread Starter
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Quote:
Originally Posted by thundercoupe9 View Post
I can put a plug and play microsquirt together, I just have to order ecu plugs and vw ignition module.

For some reason running meth kit progressively sounded like a very good idea to me, it could handle some of the extra fueling under boost.
I have an extra harness.... send me a PM with some price figures and maybe I can make it worth your while! I don't mind doing the harness ends/plugs... it was more setting up the base tune, options, and software part that I was dreading. Seriously interested though...........

As for controlling it progressively: Yes it's a good idea, but doing it the way everyone in the industry does it by trying to pulse the motor or slow-moving solenoids is no good for accuracy. On top of that, it just adds another fail point in the system (I've already had one progressive controller act wonky on me). The ideal is to have it on full blast at peak torque/cylinder pressure and have it taper off slightly up top. It's an OK compromise to have it on the skinny side of the acceptable mixture and let it spray through the whole rev range like that. It'll be a little bit on the fat side (speaking for the required water measurement, not fuel) up top, but not so much that it'll cause any problems. Short of using a water-proof fuel injector or super-fast reacting water-proof solenoid controlled down to the .1 m/s, it's the best I can do. I've never even heard of a fuel injector/solenoid that won't corrode and go tits-up when exposed to water constantly.

Attack life... it's going to kill you anyway.

Last edited by SpazOnaZX; 01-06-2014 at 11:59 AM.
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