96supercharged

Hey guys, seemed like there was some interest in my newest bike project so I figured I'd post it up. A quick note about this build, it's never been about making a lot of power. I could go down to the dealership today and have a selection of bikes with a lot more power than this thing would ever have. It's just to see if I can do it and to keep me entertained.

that said:

So here's the newest build I'm working on, I'll post up what I had on another forum to this point:

Specs and Goals:

1977 XS650 frame/engine the engine will remain mostly stock, just rebuilt.
I'm switching the engine over to fuel injection. It will be run by Megasquirt controlling fuel and spark.
The motor will be turbocharged and intercooled- if my #'s are correctly calculated, I should be getting about 88hp out of the engine, so maybe 75-80 at the rear wheel.
ZX6R front suspension and bars
Buell swingarm and rear shock
Frame will be 70% my own construction
Bike will have all the same specs as a modern sportbike regarding the rake/wheelbase/ect... However, it will be taller than most sportbikes. I've got really long legs and I like taller bikes, plus, I want to keep people from wanting to ride my bike.
Wheels will be f2/f3 style
Full brakes from ZX6R
Custom subframe and tail section of my own design
Buell headlight and windscreen
Suzuki GSXR gas tank
bunch of other stuff I'm forgetting.....

Pictures:

Tail section I molded from foam and fiberglassed:







swingarm, tank, and tail section:



Buell swingarm, was initially purchased because the warrior engine is a right side drive. I still wanted to use it, so I'm filling in the right side, and cutting a space for the chain on the left side.

Made some paper templates:





Cut the pieces out and welded them up. This is my first time working with aluminum, it's pretty fun.



smoothed the welds, the piece should be welded in place pretty soon:





Here's the frame I started with:



here's what's left:



quick mockup-



Frame progress:













That's what I've got so far. I know it looks like there's a lot of space around the engine in the frame, but the turbo is going back there, along with the intake manifold. The intercooler will be mounted vertically on the downtubes.

I've got a mockup turbo coming in the mail, also my blow off valve and Buell rear shock.

This is going to be a really involved build I hope you'll have as much fun following along as I have building it.

I'm sure I've missed a bunch of stuff, so if you have any questions feel free to ask.

thanks
Sky


Just after I wrote this I started thinking about something else on the bike and went down to look at it.

It's funny how the mind works sometimes. I was down looking at the bike thinking about another aspect of it, when I looked at my other bike, and turned the bars.

There's no way I could turn the bars on this bike with the frame the way I made it!!! Haha

So I had to cut the top bars and redo the front section so the forks would have the room needed to turn.

Old version:



New version:



It's a little tough to see what I did from those pictures, but at least now I can turn....

Got my rear shock today, sheesh, this thing is a lot bigger than I expected. Really nice part though.







Not much today, I got my blow off valve in-



Only other thing I did was shape some tabs for the subframe mounting and tacked them in place. These I used some welding rod to simulate a platform to set the tail on so I could get a better idea what it's going to look like. Also, I think I've pretty much got the height set for the swingarm so I'm going to start building the upper mounting point for the shock.







Not much I know, but thanks for looking anyway

Sky

OK, not too much to show you guys lately, been finishing my move to the coast, setting up shop in my Dad's garage

I got my new rear wheel in the other day, a couple mockup pics:



Got my turbo in the mail too, slight change of plans there. The original 14B I was supposed to get didn't show, the guy refunded me, and it worked out well actually because it made me look around some more. Got an even better setup with my new choice K04 turbo from an Audi TT:



size comparison:



Here's the most likely turbo mounting position:







I also got started on my flanges for the intake manifold I'm making. My dad had some aluminum in his shop so I started drilling:





Think it's thick enough? :yes: 1/2"



obviously they'll be shaped more eventually, but that's the basic idea.

I should have my front wheel and forks showing up soon, as soon as they get here I can start setting up the ride height of the bike and it'll start looking a little more complete.

Thanks for looking guys....
Sky

Got a fair amount of work done on the intake manifold recently:



here you can see the plenum and the throttle body feeding it, and here's a few shots that show the positioning:



tight fit, but it'll clear



In this shot you can see the holes I've cut for the runners, and also you can see my finished intake flanges:



I don't have the mandrel 90's I need to finish up the runners yet, or the alumnium injector bosses, but I should have those ordered soon. I also cut out the caps for the sides of the plenum, but I'm not going to weld those in place until everything else is welded up.

Also, I'm going to build a short bracket from the Throttle body to the upper motor mount to help support the manifold.

I'm having a blast welding this aluminum, it's really interesting material to weld, For my first major project I feel like it's going pretty good:







Also, on my previous project I cut up a handlebar I had lying around because I needed to make some spacers out of it for my calipers. All the time I was thinking I'm going to regret this because I'm going to need this eventually. Yep, sure did
So I got a length of 7/8" aluminum round stock and made sure everything was super straight and welded it on:



Anyone need an ultra long clip-on?

Now I just need to smooth the weld, cut it to factory length and tap the end for a bar end if I so choose.

Thanks for lookings guys, hope to keep updating fairly regularly but you all know how life keeps getting in the way of what we want to be doing!

Sky

Yeah buddy, got my front end in today, 2007 GSXR 600 forks and lower triple.

Looks like my assumptions are correct, the fork size is the same as ZX6r forks, so I can use my Kawi clip-ons, and also I'm going to use a Kawi upper triple.

Some pics, the bike visually is starting to come together, also I get my front wheel tomorrow, so expect to see some pics with that in place tomorrow sometime.









thanks
Sky

Got my front wheel on today! Mocked up anyway....

I'm really really liking how this bike looks right now. Should be awesome when finished:









thanks
Sky

Sorry for the delay, I was off on a trip for a few days.

Meanwhile today I did some more work on the intake manifold. It seems to be shaping up nicely so far, the injector bungs are in the mail and should be here on Thursday, but I'm clean out of argon gas, and don't really have the money for more right now, so updates might be a bit slim for the immediate future

Anyway, here's some pictures:









As you can see the runners are fully welded to the flanges, and are not even tacked to the plenum yet. A bit more work needs to be done to the tops of the runners to make them fit as well as possible.

A quick note about the runners, I was originally going to order some mandrel bent 90 degree elbows, but the thickest I could find them in was 16ga which is a waste of time trying to weld that to 1/2" aluminum. So I went to my local supply place and picked up a length of tubing which had the proper diameter I wanted. The catch? It's sch45 tubing, think that's thick enough
So quite a bit thicker than I needed, but hey, stronger is better right?

Anyway, hopefully things will turn around for me fairly quickly here and you'll get some better updates.

Later
Sky

I was able to get started on the collector for the turbo manifold:





Also I got the injector bungs in the mail, drilled the runners for them and welded one side in place. Not so happy about my aluminum welding right now, I need more practice:





A few new pictures from tonight. Got the other injector bung welded into place, still not great welding, wish I has a chance to do some scrap welding on aluminum to get my skills up to par. Anyway just a few shots of the bike together with the turbo mocked into its final position:



Everything is a pretty tight fit!





Check out my sweet exhaust



I just think this picture is cool, when was the last time you saw injectors on an XS650?



Here's a couple quick pics of the turbo manifold I'm making:

I determined awhile ago that I would be able to check the oil on this bike, so you'll notice the pipe snakes nicely around the oil dipstick tube









Masking tape is an excellent tool for mocking up tubing





That's about where I'm at now, that side that still has masking tape in the picture has been tacked into place. Due to how the head ports are placed on these engines it's impossible to build the manifold as one peice, so likely one or both sides will have a flanged section that comes apart for installation or removal.

I've got some more stuff done since these pictures were taken, but I've gotten a bit sidetracked by other things, so I'll get back going on this bike again soon, get some new pictures up. Hope you guys have enjoyed looking at all the pictures, feel free to comment away positive or negative I like feedback.

So, been awhile since I've actually had any updates on this thing. Combination of factors; welder is at work, working on other things, kinda burned out on it for awhile, that sort of thing

Anyway, just a quick post to let you know what's new.

Got a few parts in, got my Kawi upper triple:



Here's my new intercooler. It's a perfect size! It originally came as a side mount intercooler on an Audi S4:



This probably isn't the final mounting position, but I'm trying out a bunch of different spots. It will be mounted to the downtubes in some fashion though.

Here's a couple of distance shots showing how the bike looks currently. Also you can see my 2005 ZX6R seat:







Got my cush drive in:



This is what sucks, because of the gearing in these bikes I need to use a 30 tooth sprocket, that's pretty small. So there's going to be lots of milling on this cush drive to make it compatible with the new sprocket. I'll also have to cut an adapter plate:



My brother owns a 2004 ZX6R and he recently got hit by a car. He's ok, but they totalled the bike out. He bought it back and is parting it out. He's going to give me the complete braking system and rearsets! Whoohoo, stuff like this never happens!

Also, here's what's been keeping the majority of my attention:



I've been trying to teach my wife to ride, but she gets really intimidated by bikes. So I tried to find the least intimidating bike EVER

I've spent the last month refurbishing it, it's almost ready to go, just a little bit more work.

It's going to be a surprise for her, don't ruin it!

Anyway, hope to start back up on this soon and get some work done.

thanks for looking
Sky

kings_blend

nice work dude!

Lee G

I really like it, Your aluminium welding is good for a beginner. All the forced induction bikes I know of ended up in ditches.

Kevin

Interesting project.

RC000E

Where's the other bike...you still riding it, or did you sell it?

This thing looks really tall for sure, so it'll be interesting to see it more complete. Keep it going...I'm in for the finish.

96supercharged

Yea I've been riding it all over the place. The thing apparently is completely reliable right now, so I haven't touched it.

Here's a few new pics of it:







That's really the nice thing about the new build, right now I have a bike I can ride and enjoy, so I can take my time on the new bike and do it right.

scartail

Nice project! I would like to turbo by '76 CB550 one day.

I ran into this guy's website about a turbo xs as well. you probable have already seen it. http://www.xs650.org.au/kev%27s%20turbo.htm

He milled his on jugs and welded up his own frame!

Flashmn

Thats so cool its beyond awesome!

chrisbmx68

great work so far, I feel like that turbo might end up being a tad big? If it doesn't feel good after you are all done you could probably get a k03 from a 1.8t which is a tad bit smaller but has the same flange etc.

got wide

hey i have a 81 kaw 440 that i cant get running cuz i know **** about carbs and the old ignition stuff. i'd love to swap to injection, how much did it cost you to change over? and what all was involved as far as adding or changing sensors?

logic-dsm

Just out of curiosity, have you done any other Megasquirt projects? (I have a few friends who swear by it for their automotive applications.) You're going to have a lot of fun with that when you're done.

got wide

this pic made me lol. the whole head up someones *** image with the tail on the helmet, idk im an idiot.

but seriously i think you just took the record for the longest single post, lol. that was like 6 pages of stuff on the other forum. thanks for adding it and good luck!

EchaKqulo

Man!!! I have no other words than YOU ARE CRAZY!!!!

Keep up the good work, your creation amazed me!!

madblkscientist

i always wanted to build a chopper but it looks like to much for me to take on by myself but u inspired me ur bike r kooler than kool bro keep it up

my95dc2

wow, sky, your builds are amazing. I just found myself a cherry 79xs1100 but i dont have the time or equiptment to do what you do. keep it up man

chrisbmx68

My 84 rabbit is on megasquirt its pretty popular due to price with us VW guys. It works well enough as long as you know what you are doing when putting the PCB together, or buy it pre assembled from a reputable builder. 99% of the problems I have seen people have are because they didn't wire it correctly or had parts fail on the pcb due to installation or soldering error.

For the price Its good enough but if I did it again I would use something else probably.

thegatekeeper14

this is amazing ive always wanted to make my oun bike

jfoster

iTrader: (1)

Excellent work and really interesting project. I really like my XB9 but a turbo project bike might be in my future... looks like too much fun!

Smokinsax

what a sick *** project...looking forward to seeing some updates

96supercharged

I sure wish I had some updates to give you, here's a funny vid instead:

http://www.youtube.com/watch?v=UVCpwj9N-IQ

SD_Lurker

iTrader: (4)

Wooden tables? Your just as bad as me, possibly worse.

xci_ed6

Wood tables are great! Won't nick, scuff, conduct electricity, and they are cheap so you can drill them to hold stuff down without caring about replacement cost.

I also have a wood bike table, I think I built it strong enough to set my civic on.

jamievk

No updates on the xs650 forum
http://650rider.com/index.php?name=F...r=asc&start=24

JDMCRX

iTrader: (2)

nice work man post more pics

daddy

iTrader: (1)

Great build. you do awesome work!