alexm963 Posted January 3, 2017 Share Posted January 3, 2017 Figured I should start a thread to track my progress. Been thinking about doing this for a while and finally decided to take the plunge. This is my first bike and has been a blast to learn to ride and work on. I was planning on building an intake for the bike over the winter similar to the Hordpower option. After taking some measurements and lying to myself about what things cost I decided to turbo the bike. I've had several turbocharged cars over the years and am familiar with all the components and what it takes to be reliable. I also have a buddy who is a certified dyno tuner and builds 500hp+ WRXs for fun. I have access too mills, lathes, and welders at work. I've been slowly ordering a few parts over the last few months and now that I'm on winter break I had a chance to get started. First up was the manifold. The turbo is off an Audi TDI. The flanges I had laser cut by a supplier we use at work. I ordered some 1.625" OD, 11g, 180* bends from Columbia river. Great response time from them. And great quality bends. Then I took measurements off my stock exhaust to make some head adapters. Turned those out at work last week. This weekend was dedicated to fabbing up the pipes. I don't have a welder at home so I had to do some guess and check while running my back and forth to work and tigging up the tube. The merge isn't perfect and I have some gaps to fill but I'm pretty happy with how it is turning out. I'll hopefully finish it up tomorrow and post and update. Link to comment Share on other sites More sharing options...
angus Posted January 3, 2017 Share Posted January 3, 2017 There's a guy on the ZRX forum that has made a turbo kit for several different motorcycles including a Suzuki DR. I've been tempted to ask him if he'd like to play with my FZ-07 but it looks like you've got it covered pretty well . Good luck and be careful! Link to comment Share on other sites More sharing options...
ddog Posted January 3, 2017 Share Posted January 3, 2017 Goals. Props to you man I'm excited to see how this project turns out. Link to comment Share on other sites More sharing options...
mossrider Posted January 3, 2017 Share Posted January 3, 2017 This is great! Make sure you leave enough room for the front wheel to stroke through its travel. (seen others run into probs.) Link to comment Share on other sites More sharing options...
alexm963 Posted January 3, 2017 Author Share Posted January 3, 2017 I put a ratchet strap on the front wheel and fully compressed in before starting. Should be plenty of room with it's current location. Link to comment Share on other sites More sharing options...
Premium Member blackout Posted January 3, 2017 Premium Member Share Posted January 3, 2017 Awesome project! Craig Mapstone Upstate New York Link to comment Share on other sites More sharing options...
Beemer Posted January 3, 2017 Share Posted January 3, 2017 Any idea how much extra h.p. this will add and how much extra weight is it? Cool project, btw! Beemer Link to comment Share on other sites More sharing options...
chademinent Posted January 3, 2017 Share Posted January 3, 2017 SWEET! Im getting my turbo tomorrow! Your work looks great so far. My Build Thread http://www.fz07.org/thread/5796/hulagn-2015-fz07-build Link to comment Share on other sites More sharing options...
chademinent Posted February 6, 2017 Share Posted February 6, 2017 Any updates? Did you get your manifold re-done yet? My Build Thread http://www.fz07.org/thread/5796/hulagn-2015-fz07-build Link to comment Share on other sites More sharing options...
Beemer Posted February 6, 2017 Share Posted February 6, 2017 Inquiring minds want to know. Beemer Link to comment Share on other sites More sharing options...
alexm963 Posted February 6, 2017 Author Share Posted February 6, 2017 Yeah sorry about the lack of updates. I got the manifold done. I need to re wrap it with exhaust wrap. The ends were too thick with a double layer I couldn't get the bolts back on to mount it fully. I started cleaning up the flange for the outlet exhaust. School and work have consumed my time. Hopefully this weekend I'll have time to start on the rest of the exhaust. I'm terrible about taking pictures too. Link to comment Share on other sites More sharing options...
chademinent Posted February 6, 2017 Share Posted February 6, 2017 Yeah sorry about the lack of updates. I got the manifold done. I need to re wrap it with exhaust wrap. The ends were too thick with a double layer I couldn't get the bolts back on to mount it fully. I started cleaning up the flange for the outlet exhaust. School and work have consumed my time. Hopefully this weekend I'll have time to start on the rest of the exhaust. I'm terrible about taking pictures too. Sweet! Thanks for the update. Pictures or it didn't happen 8-) My Build Thread http://www.fz07.org/thread/5796/hulagn-2015-fz07-build Link to comment Share on other sites More sharing options...
alexm963 Posted February 8, 2017 Author Share Posted February 8, 2017 While this isn't physical progress, I had some time to design this decal while I was not paying attention in my measurements class. Link to comment Share on other sites More sharing options...
mossrider Posted February 8, 2017 Share Posted February 8, 2017 Sure beats listening. Link to comment Share on other sites More sharing options...
Beemer Posted February 8, 2017 Share Posted February 8, 2017 While this isn't physical progress, I had some time to design this decal while I was not paying attention in my measurements class. The tire is thicker towards the rear. A result of not paying attention in measurements class. Ha! (jk) Good effort, not bad. When you do take pics they're good I have to say. Beemer Link to comment Share on other sites More sharing options...
chademinent Posted February 8, 2017 Share Posted February 8, 2017 While this isn't physical progress, I had some time to design this decal while I was not paying attention in my measurements class. Must have been an intriguing class...lol My Build Thread http://www.fz07.org/thread/5796/hulagn-2015-fz07-build Link to comment Share on other sites More sharing options...
alexm963 Posted February 8, 2017 Author Share Posted February 8, 2017 While this isn't physical progress, I had some time to design this decal while I was not paying attention in my measurements class. The tire is thicker towards the rear. A result of not paying attention in measurements class. Ha! (jk) Good effort, not bad. When you do take pics they're good I have to say. Well it's not a tire. It's the cold side of a turbo. And those are my initials in the lower blades. I guess our wheels do have a similar look to them. Link to comment Share on other sites More sharing options...
Beemer Posted February 8, 2017 Share Posted February 8, 2017 The tire is thicker towards the rear. A result of not paying attention in measurements class. Ha! (jk) Good effort, not bad. When you do take pics they're good I have to say. Well it's not a tire. It's the cold side of a turbo. And those are my initials in the lower blades. I guess our wheels do have a similar look to them. Ha! I see it now. The guy sitting on it made me think it was a tire. Slow day. Waiter, more coffee! Beemer Link to comment Share on other sites More sharing options...
alexm963 Posted February 9, 2017 Author Share Posted February 9, 2017 Another small update. I took the exhaust wrap off the manifold and sprayed it with BBQ coating. Its supposed to be good up to 1200F. I did like 5 coats so we'll see how it lasts. I like it a lot better than the wrap too. Also today was another exciting day in Measurements. So I overlaid the flow rates at 2500-10k RPM on the compressor map for the turbo I have. Looks like it will work fine. I'm almost at the choke point at 10k. I haven't decided what max boost I'll be running. I graphed up to 10psi. I'll probably start at 4-5psi and tune from there. Link to comment Share on other sites More sharing options...
Beemer Posted February 9, 2017 Share Posted February 9, 2017 Looks good! Beemer Link to comment Share on other sites More sharing options...
Premium Member blackout Posted February 9, 2017 Premium Member Share Posted February 9, 2017 Yup, looks good! I never liked the wrapping. It never stayed on well for me. If the project goes well and the paint comes off, have it ceramic coated. So, the exhaust tubing is not stainless? What wall thickness did you go with? .063"? I'm fabing an exhaust now in .063" 304 stainless only because I'm new to TIG welding and did not want to worry about blowing through .049". Craig Mapstone Upstate New York Link to comment Share on other sites More sharing options...
alexm963 Posted February 9, 2017 Author Share Posted February 9, 2017 No I went thick. It needs to support the weight of the turbo and the rest of the exhaust. It's .120" wall. Link to comment Share on other sites More sharing options...
Premium Member blackout Posted February 9, 2017 Premium Member Share Posted February 9, 2017 No I went thick. It needs to support the weight of the turbo and the rest of the exhaust. It's .120" wall. That makes sense. Craig Mapstone Upstate New York Link to comment Share on other sites More sharing options...
Global Moderator sorkyah Posted February 10, 2017 Global Moderator Share Posted February 10, 2017 You arent going to have an external bracket for the support? Those exh studs arent all that strong, neither is the alu they're screwed into. I bent one removing the stock nut when i swapped on my yoshi pipe. im waiting to see how you plan on mating the output to the intake, go through the right scoop perhaps? ATGATT... ATTATT, two acronyms I live by. Link to comment Share on other sites More sharing options...
alexm963 Posted February 10, 2017 Author Share Posted February 10, 2017 You arent going to have an external bracket for the support? Those exh studs arent all that strong, neither is the alu they're screwed into. I bent one removing the stock nut when i swapped on my yoshi pipe. im waiting to see how you plan on mating the output to the intake, go through the right scoop perhaps? Well that is a concern with the studs. I may add a bracket to the outlet exhaust to help out. The intake is the next big piece after I finish the outlet exhaust. New plenum, intercooler, piping. blow-off valve. I'll get plenty of aluminum welding practice. Link to comment Share on other sites More sharing options...
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