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General Category => FJ Project Writeups => Topic started by: backstreetheros on August 18, 2012, 12:37:54 PM

Title: fj1200 turbo "thug"
Post by: backstreetheros on August 18, 2012, 12:37:54 PM
Hi all, where should i start?!
I'm mark, 24 from Dorset.
As youll see from the bike im a plumber
Just bought a fj1200 ( well more like an engine.)
Thought id put some pictures up here for you all tp have a laugh at!
Need to know what i need for wiring too.
Aparantly its a 1991 3xw motor, DrZ 400 front end, I have used the following.
Impreza turbo td.04. And flanges.
Rover 200 exhaust manifold.
Mercedes vito water pump.
Ford focus power steering bottle.
And many more bits I've forgot.
I'll try upload some pictures in the order they were taken.
Cheers. Mark.
(http://fjowners.com/gallery/3/2783_18_08_12_12_04_50.jpeg)
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on August 19, 2012, 05:22:07 AM
Hi mate,nice chop there! im up in the Newcastle area,and just starting an FJ12 chop myself.
Heres mine in the mock up stages.
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/chopper%20stuff/102_3282.jpg)

Seeing your user name,i guess you probably read BSH magazine?? A couple of months ago,my mates bike was on the front cover/centre pages (NSU supercharged chopper)? Im now the owner of the supercharger set up from that bike,and im looking to do a supercharged FJ chop. The only problem is,no way will the supercharger fit in the space on my frame. Doh! i do however have a mitsubishi TD04 turbo. :good2:
Im also doing a couple more chops at the moment,but they are suzuki powered. So have no place here. :lol:
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/chopper%20stuff/102_3336.jpg)
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/chopper%20stuff/102_3299.jpg)

Do you have any more pics (please) of your build???? Im eager to see more!

http://www.fjowners.com/index.php?topic=7236.0 (http://www.fjowners.com/index.php?topic=7236.0)
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 20, 2012, 12:10:25 PM
[imgC:\Users\f\Desktop\bike\mock up.jpg]http://[/img]
(C:%5CUsers%5Cf%5CDesktop%5Cbike%5CIMAG1043.jpg)
(http://C:%5CUsers%5Cf%5CDesktop%5Cbike%5CIMAG1044.jpg)
(http://C:%5CUsers%5Cf%5CDesktop%5Cbike%5CIMAG1045.jpg)
[imgC:\Users\f\Desktop\bike\IMAG1046.jpg]http://[/img]
[imgC:\Users\f\Desktop\bike\IMAG1052.jpg][/img]
[imgC:\Users\f\Desktop\bike\IMAG1053.jpg]http://[/img]
[imgC:\Users\f\Desktop\bike\IMAG1054.jpg][/img]
[imgC:\Users\f\Desktop\bike\IMAG1055.jpg]http://[/img]
[imgC:\Users\f\Desktop\bike\IMAG1056.jpg][/img]
[imgC:\Users\f\Desktop\bike\IMAG1057.jpg]http://[/img]
[imgC:\Users\f\Desktop\bike\IMAG1058.jpg][/img]
[imgC:\Users\f\Desktop\bike\IMAG1061.jpg][/img]
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on August 20, 2012, 12:21:46 PM
LOL,the pics havent worked!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 20, 2012, 12:30:26 PM
up-pipes mocked up
(http://fjowners.com/gallery/3/2783_20_08_12_11_21_14.jpeg)

manifold made with flange, extreme size i know
(http://fjowners.com/gallery/3/2783_20_08_12_11_23_19.jpeg)

turbo mounted
(http://fjowners.com/gallery/3/2783_20_08_12_11_25_02.jpeg)

(http://fjowners.com/gallery/3/2783_20_08_12_11_27_17.jpeg)

more to follow...
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 20, 2012, 12:46:28 PM
turbo radiator made

(http://fjowners.com/gallery/3/2783_20_08_12_11_34_08.jpeg)


turbo pipes without intercooler (wish the postman would hurry up.)

[imghttp://fjowners.com/gallery/3/2783_20_08_12_11_35_52.jpeg]http://[/img]


ford focus power steering fluid bottle for my header tank for water cooled turbo.
(http://fjowners.com/gallery/3/2783_20_08_12_11_38_08.jpeg)


need to adjust the lock stops slightly to stop the forks hitting the radiator.
(http://fjowners.com/gallery/3/2783_20_08_12_11_39_29.jpeg)


(http://fjowners.com/gallery/3/2783_20_08_12_11_40_53.jpeg)

ghetto seat i made
(http://www.fjowners.com/index.php?action-gallery;sa=view;id=3751)

child killer side exit may need a baffle or guard :wacko2:

(http://fjowners.com/gallery/3/2783_20_08_12_11_45_14.jpeg)
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 20, 2012, 12:53:04 PM
(http://fjowners.com/gallery/3/2783_20_08_12_11_43_38.jpeg)

(http://fjowners.com/gallery/3/2783_20_08_12_11_52_14.jpeg)
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on August 20, 2012, 02:54:21 PM
I can now see what you meant when you said you are a plumber! lol.
I must say,even if the bike was normally aspirated it would be cool,the turbo idea takes things to a new level. I admire your ingenuity. Who made the frame?? I like the lines.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 20, 2012, 03:26:32 PM
haha i want people to look at it and say "what the hell is that?"
i dont know who made it, its drz400 front end with custom rear and fj12 mounts
has shortened battery box made out of ammo box
i absoloutly hate these chrome shiney gimp machines that everyone thinks are cool but really you have to ride them so fast so no-one sees you in your gimp suit haha!
i wanted a chop but wanted something that wouldnt leave me looking stupid off the line
i need some carbs!! know for a set? they are expensive on ebay!!
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on August 20, 2012, 04:46:39 PM
randy at rpm sells new carbs $400 I think
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on August 20, 2012, 05:38:53 PM
I might be able to put my hand on a set of fj carbs? I'll get back to you tomorrow. :good2:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 20, 2012, 05:53:20 PM
I'll be the happiest man alive if you can find me a set! Need anything plumbing? I prefer trades to keep my build budget down and makes me feel like I spent less on it haha!
Title: Re: fj1200 turbo "thug"
Post by: Firehawk068 on August 21, 2012, 10:20:29 PM
Quote from: backstreetheros on August 20, 2012, 12:46:28 PM
turbo radiator made
(http://fjowners.com/gallery/3/2783_20_08_12_11_34_08.jpeg)
Looks really cool, and strange, but would this dissipate enough heat without any heat-sink material(cooling fins)?????

You could try sourcing a used radiator from a snowmobile, or other powersports vehicle.
My El-tigre had a much smaller radiator than the device you've built, and would cool approx 120hp worth of two stroke engine.......although I never rode it above 30 or so degrees. :biggrin:
Maybe one from a 2 stroke dirt bike would work.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 22, 2012, 01:01:02 PM
Well there is 6 meters of copper pipe there, plus turbo is well in the wind, and oil coiled, if not ill change to something else, or more pipe haha.
I'm going to make something to cool the oil more.
I'm just using things I've got laying around.
Intercooler didn't turn up today so the bike is on its own tonight!
Got throttle cables mounted, grips
Need to weld the seat on when my springs turn up too
Still a long way off yet, still on the hunt for carbs too.
Title: Re: fj1200 turbo "thug"
Post by: Pat Conlon on August 22, 2012, 04:57:29 PM
Question Mark, how is all that weight from the turbo and plumbing supported? Not by just the exhaust studs I hope.....

Andy is correct re: timing (unless your wastegate is set for very low pressures) you are going to need a way to retard the timing when your manifold pressure sensor sees boost. If not:  :bomb:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 22, 2012, 05:16:02 PM
At this moment in time its all hanging off the studs but as you can see the bike is in the shed. The welder isn't so I'm trying to avoid putting my back out... Again.... Trying to.get it in and out lol.
There will be a solid bracket from the nearside to support the rest of the exhaust
I'm planning on welding the seat, exhaust bracket, intercooler bracket and fuel pump bracket at once to save effort.
The bike is slightly weighted to the right so intercooler and whatever other crap I can find I'll balance on the left side!
Have to modify the spring in my dump valve and fit that too.
I'm starting the bike off on extremely low boosts and working up.
I think one of those programmable ignitions may make sence.
Was also thinking water/methanol injection to kick in at higher boost.
Need a waters/methanol resivour then! Running out of places to fit it on a bike.

How much will the standard boost advance actually change the ignition? Surely this would help before I have bought the programmable box?.

I still have the fuel pressure regulator, carbs and ignitor to get yet.
And a boost advance thing.
That's what I need to make it run,
To make it ride... Different matter.
Title: Re: fj1200 turbo "thug"
Post by: Pat Conlon on August 22, 2012, 09:06:48 PM
Mark, let me see if I can shed some light.
The stock FJ ignition "power boost" feature is not what you need, so don't confuse it with anything due to forced induction.
Apples and watermelons.
The stock FJ has a ignition which runs ~35 degrees advance (BTDC) starting ~ 4k rpm and above. The power boost feature senses higher vacuum levels when the throttle plates close and then advances the ignition to ~40 to 50 degrees to flash off excess fuel in the intake mix.
According to Randy @ RPM this is a emissions control feature.
As I painfully learned, racers don't use this "power boost" module, they just disconnect it and plug the vacuum port and run the stock ignition advance.
Here's a thread on this subject: http://www.fjowners.com/index.php?topic=6739.0 (http://www.fjowners.com/index.php?topic=6739.0)
Look at the different timing maps. Look at the vacuum levels.
Remember that the vacuum signal is taken between the plates and the engine, so when the throttle plates close the vacuum goes up.
The "power boost" feature is of no use to you. It's a emissions thingy.

Cheers lad.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 23, 2012, 01:49:41 AM
thank you!!
I finally understand now!
Surely this is in essence like anti-lag. But without adding more fuel.
I'm glad you explained it before I went and bought one.
This wouldnt do anything on my bike.
So back to just the ignitor then.

I need to find an ignition key off something so people can't steal it as easily.
Still lacking in information regarding high pressure tappings on the block to feed the turbo.
Can anyone shed any light?
Thanks again for everyone's help so far in teaching me the fj-way!
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on August 23, 2012, 12:04:21 PM
Hi Mark,ive been onto my friend about carbs,and he's undecided about selling them. He's built a new chop,which is being finished this week,running a single weber 45 carb. I think he wants to make sure the engine runs ok with this,as he's doing his first run on the bike from the north east of england down to Bedfordshire! brave man.
Check this link out to see somebodies Turbo'd FJ.
http://www.oldskoolperformance.com/forum/viewtopic.php?f=6&t=723 (http://www.oldskoolperformance.com/forum/viewtopic.php?f=6&t=723)

The builder seems like a nice bloke,offering good advice to people on forums,so he might be worth checking out.
Im very much like you,in that no cash seems to change hands on builds,more favours for favours or swopping of parts. :good2: If id known about this a week or two ago,i would have sent you an unwanted turbo intercooler. Too late now though,as its been taken by a friend.
Title: Re: fj1200 turbo "thug"
Post by: Travis398 on August 23, 2012, 05:44:46 PM
Quote from: Pat Conlon on August 22, 2012, 09:06:48 PM
racers don't use this "power boost" module, they just disconnect it and plug the vacuum port and run the stock ignition advance.

They do use it, and they hook it up just like the bike.
Title: Re: fj1200 turbo "thug"
Post by: Travis398 on August 23, 2012, 05:50:17 PM
Quote from: backstreetheros on August 20, 2012, 03:26:32 PM
its drz400 front end
what part?
I see your forks are FJ forks
Title: Re: fj1200 turbo "thug"
Post by: racerrad8 on August 23, 2012, 05:59:42 PM
We don't use it in our Legend cars.

Randy - RPM
Title: Re: fj1200 turbo "thug"
Post by: Travis398 on August 23, 2012, 06:05:14 PM
Define we? 600 says this.....don't they?

(http://www.haleyracingclub.com/images/Legends_color_wiring_diagram.jpg)
Title: Re: fj1200 turbo "thug"
Post by: racerrad8 on August 23, 2012, 06:37:32 PM
That is the wiring diagram they issued back in 1996...but in 98 they had to change over to the XJR black box as that what Yamaha started supplying them with.

If you look at the timing charts, the "vac sensor" as they have labeled it, causes the ignition timing to spike at high vacuum (closed throttle). We found that the car would actually accelerate when the timing jumped at the point when the throttle was released. (not what you want when trying to slow for a corner)

So, back in 96 when I won 23 of the 24 races I ran in I removed the sensor, added the base timing and that is what we have been doing ever since.

If you look at the timing curve on the chart below, it shows the timing at 37* at 9000 rpms, but when vacuum is supplied to the "boost" sensor the timing jumps to 50*. This is done to burn the excess fuel in the cylinders when the throttle plates are slammed shut on decel.

(http://i949.photobucket.com/albums/ad337/craigo987/FJ11001984ServiceManual269-1.jpg)

Today USLCI (600 Racing) says you have to use their "red box" since it is better than the O.E. parts and they surely will not give you any assistance with the black box parts.

Randy - RPM
Title: Re: fj1200 turbo "thug"
Post by: Travis398 on August 24, 2012, 06:03:35 PM
Quote from: racerrad8 on August 23, 2012, 06:37:32 PM
That is the wiring diagram they issued back in 1996...but in 98 they had to change over to the XJR black box
Randy - RPM

I assumed we were talking about 91 FJ ignition here. I don't dispute anything you are saying.......But.... the reality is people are still using them (91 FJ ignition)  and they are still using the boost sensor.  I doubt any of them have ever won 23 out of 24 races though.

Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 25, 2012, 05:40:11 AM
Cheers for putting up the wiring diagram, i have to wire it up next week as my ognitor hasn't arrived yet.
Bought a set of carbs on ebay so hopefully ill get it to fire before I connect the plenum.
I'm not going to bother witg the boost sensor as frankly I don't want it boosting on shutdown and throttling into corners. I'll try get a video of first fire.
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on August 25, 2012, 06:14:10 AM
Thanks too you blokes, i think i now know why my fj has been speeding up when throttle is closed , i thought it was carb
,but seems its timing, i had done the 5 deg ignition advance mod, but also fitted an aftermarket cdi, with no vacume advance,  so set timing to standard,  see if thats fixed it,    :flag_of_truce: sorry to hack your thread  but wanted to say thanks  (popcorn), , bring on the turbo chopp vid  :good2:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on August 31, 2012, 07:19:52 AM
Please help!!!
I wired the bike to the above diagram
Does it matter that i have a 3xw motor, pickup and coils
But i have a 3cv ignitor!
When I attatched the live for coils and ignitor it shorter out, now is dead as a doornail.
No spark atall.
Everything else is wired as per diagram but I do have a spare wire from timing pickup. Orange?
Have i just fried my new ignitor??
Im gutted!
Title: Re: fj1200 turbo "thug"
Post by: JMR on August 31, 2012, 09:44:21 PM
Quote from: racerrad8 on August 23, 2012, 06:37:32 PM
That is the wiring diagram they issued back in 1996...but in 98 they had to change over to the XJR black box as that what Yamaha started supplying them with.

If you look at the timing charts, the "vac sensor" as they have labeled it, causes the ignition timing to spike at high vacuum (closed throttle). We found that the car would actually accelerate when the timing jumped at the point when the throttle was released. (not what you want when trying to slow for a corner)

So, back in 96 when I won 23 of the 24 races I ran in I removed the sensor, added the base timing and that is what we have been doing ever since.

If you look at the timing curve on the chart below, it shows the timing at 37* at 9000 rpms, but when vacuum is supplied to the "boost" sensor the timing jumps to 50*. This is done to burn the excess fuel in the cylinders when the throttle plates are slammed shut on decel.

(http://i949.photobucket.com/albums/ad337/craigo987/FJ11001984ServiceManual269-1.jpg)

Today USLCI (600 Racing) says you have to use their "red box" since it is better than the O.E. parts and they surely will not give you any assistance with the black box parts.

Randy - RPM
Well that stinks.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 06, 2012, 09:39:51 AM
on the upside i got my carbs, throttle and cables through!
i was like a cheshire cat opening my post!! :yahoo:

today i've got my million jubilee clips to hold it together!

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-prn1/542363_10151135829005827_435470874_n.jpg)

the old mitsubishi shogun intercooler pipes got ditched for some samco hoses that came on my intercooler, but the intercooler is way too big for the bike so not going to run one for a minute.

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/578622_10151145925705827_1146577010_n.jpg)

will have to get on and do some more work on it but been chaotic with work!
good for business, bad for chopper building
Title: Re: fj1200 turbo "thug"
Post by: Dan Filetti on September 06, 2012, 10:33:16 AM
I am following this build with interest.  At first, I must admit, it seemed as if you would never actually get the thing running under it's own power, for anyone of a thousand reasons that stymie ground up garage builders attempting such an ambitious effort.  

However, it's looking more and more as if I maybe wrong.  From where I sit, it now seems as if your stick-to-it-iveness may well get this project up and running; kudos.

That said, I was wondering about the steel trellis frames that are so often used on chopper-build projects.  I know it's been done successfully for many years, and Ducati uses this approach to great effect, as another example.  Yet, when I look at this thing,  it sure seems like there's not enough there to keep that motor from twisting itself out of that frame under hard acceleration/ deceleration. Also, how will the weight of the bike not flex that frame laterally given the considerable inertia and gyroscopic forces at play while riding, especially in a corner?  I suppose you have taken these questions, and others like them, into mind?

It's the visceral physics that usually kills or injures the experimental types, seems to me.

Just wondering.

Dan
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 07, 2012, 07:25:55 AM
Thanks for your interest, yeah I know a lot of people who doubt me with projects but as with previous bike restos. I've allways succeeded.
The whole idea was to make the project difficult, scary and to show what you really can do with scrap yard parts. Shiney isn't everything haha.
The frame is HEAVY! im sure it will be ok for this application due to being so heavy guage. If I have space for some braces after all the pipework I may weld a few in for good measure. It's not a sports bike so I doubt it will undergo as much forces as their frames do, but they consentrate on structural rigidity and saving weight. Weight doesn't come into my list of issues. It takes 4 lads to lift it!
I will do whatever it takes to make it work.
At the mkment I'm looking for a 12v oil pump so I can run a completely seperate oil system for the turbo.
I think this is a more suitable idea.
I need a different cdi now as mine was the wrong one and is now fried.
I'll get a video up when i get it running then once its running properly its going to my friendly bike garage where I'm having all the brake and clutch lines done properly.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 07, 2012, 08:41:59 AM
got my smaller jubilee clips through the post today for my 10mm fuel lines
cheers ebay!!
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/260182_10151147390850827_1577939400_n.jpg)

still looking for a sensible place to mount my coke can sized fuel pump! may mount it by the battery box but need to keep the fuel pressure regulator as close to the carbs as possible for accurate fuel pressures.
going for a malpassi petrol king with boost fuel advance.

will eventually mount some ghetto boiler pressure gauges infront of the handlebar mounts on the tank i think.

might need to put that on a bit better as its touching the frame, need to slice a couple mm of the silicone hoses
got to link up the pipes off the plenum to pressurise the float bowls and the top of the diaframs.
need to steal some more rubber hose before i get round to that and find 2, 2-into-1 T's to link the 4 float bowl overflows to the 2 plenum connections...

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/561480_10151147402545827_1522654964_n.jpg)

i'm not going to bother with a choke as the rack is easily pulled by finger when sitting on the bike.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 07, 2012, 08:48:59 AM
here's a picture of my old rat bike, this thing was fun!
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-prn1/11038_191569855826_5324974_n.jpg)

wish i could have those wheels on the fj...
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 07, 2012, 08:55:41 AM
and a couple other bikes i've had over the years...
always been more of a car man but got a secret obsession with bikes...

(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/295_20958600826_5723_n.jpg)
when one Husqvarna WR400 2 stroke isnt enought.... buy two!!

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215273_10150167454110827_608019_n.jpg)
little chicken chaser CR125

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215674_10150166355915827_1622309_n.jpg)
Wanted something with a bit of tourque so got the KLR600... this was useless off road but very impressive inbuilt decompression valve
you wouldnt kick it over without it!! :wacko2:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 13, 2012, 04:05:11 PM
Well the bike has been on the back burner for a while as my business is keeping me well occupied at the moment,
Had a half hour with the bike this afternoon and put on some more jubilee clips from the carbs to the engine, tricky as they foul the throttle if you dont put them in the right place, also rem
oved my shortened ammo box as going to need to come up with a
smaller box seeing as i have to mount the fuel pump, oil pump, oil tank and possibly oil cooler in this space aswell as a battery :dash2:
It's all turning into quite a squeeze even on a bike as big as this!
My oil pump which is 12 lpm brass and stainless should be plenty man enoygh
Going to drill out the banjo bolts on the turbo for better oil flow.
I will try get some more pictures up when I get a chance.
Will be purchasing a dynotek 2000 ignition for the bike soon too.
Does anyone make a sandwich plate for the oil filter so I can run 2 oil coolers for the engine and one for turbo?
Or is there somewhere I can tap the block?
I'm no fj1200 expert unfortunately!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 23, 2012, 05:03:43 PM
Been still very busy so not had time to do alot. Got a chance yesterday to make a bracket for the oil tank and mount that. Incase you were wondering the tank is a vintage warmwell copper hot water bottle and the bracket is a cage of 22mm copper pipe and fittings. The cap from the hot water bottle made a small but cool oil filler cap. Got the oil drain from the turbo done too. My oil pump and oil cooler arrived. The pump is a seaflo brass gear driven pump and the oil cooler is from  a 1998 subaru impreza. Im going to mount the numberplate onthe side like every other chop. But i am going to mount the oil cooler behind it with a gap so air can still circulate yet its not such an eye sore.
Dynatek ignition.
Finish the oil lines
Fill it up witg fluids
some form of switch plate to control all the pumps.
fuel pressure regulator and fuel pipes
then it should run! Getting excited now.
I will be sure to film the first start attempt for you lot
Pictures soon
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 25, 2012, 05:03:46 PM
So this evening i thougjt id come up with an idea for more cooling...
Thats untill i stumbled upon rpm racing...
They make all the parts i have been dreamkng about!!
Fj-aftermarket oil adapters.
Fj to spin on oil filter! Which i could probably get a sandwich plate on too...
Oil galley plug with tapping for oil temp or pressure!
The only thing i cant find is the two blanking plates on the front of the lower forks... Mine are missing...
Has anyone purchased from them who also live in england?
Is postage reasonable?
I am so excited to make my order!!!
So happy aomeone makes all the parts i need!!!
If you havnt already... Check them out... Legends!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 27, 2012, 12:31:16 PM
couple of pictures...
(http://sphotos-a.ak.fbcdn.net/hphotos-ak-prn1/644757_10151170782905827_706914435_n.jpg)
thought i'd get a bit creative with some copper pipe

(http://sphotos-f.ak.fbcdn.net/hphotos-ak-snc6/228006_10151170784700827_1396035748_n.jpg)
made the oil tank and bracket and done the return from the turbo
yet to get the welder out again and do the oil pump brackets and oil cooler brackets...
will get on it soon.
(http://sphotos-f.ak.fbcdn.net/hphotos-ak-snc6/229277_10151170788210827_1999793411_n.jpg)

will get some more pictures up soon but lost the cable from my phone to my laptop... which is also the cable for my digital camera! :dash2:
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on September 27, 2012, 05:18:24 PM
How heavy will this beast be mate :good2:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 29, 2012, 10:42:01 AM
Extremely!! Once its on the road ill take it to the bridge and see what it weighs.
Got myself a mocal spin on oil cooler sandwich plate and some hoses yestedday and today i sprayed an old helmrt i had . Got carried away and went to halfords to get clear laquer and came out with a 14AH Bosch battery for the bike.lools like im goimg to have to moumt that ammo box after all because yhe battery fits perfect. Will have to get the ignition controller in this box too!
More pictures soon.
i can lift the front wheel of this bike off the floor on my own... But it is heavy...
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 29, 2012, 10:50:33 AM
(http://[url=http://sphotos-g.ak.fbcdn.net/hphotos-ak-snc6/s480x480/10581_10151177885380827_507503979_n.jpg%5Dhttp://sphotos-g.ak.fbcdn.net/hphotos-ak-snc6/s480x480/10581_10151177885380827_507503979_n.jpg%5B/url%5D)
(http://[url=http://photos-a.ak.fbcdn.net/hphotos-ak-ash4/c0.81.720.478/s320x320/251388_10151177724745827_660325636_n.jpg%5Dhttp://photos-a.ak.fbcdn.net/hphotos-ak-ash4/c0.81.720.478/s320x320/251388_10151177724745827_660325636_n.jpg%5B/url%5D)
Title: Re: fj1200 turbo "thug"
Post by: FJmonkey on September 29, 2012, 11:20:37 AM
Quote from: backstreetheros on September 29, 2012, 10:50:33 AM
(http://sphotos-g.ak.fbcdn.net/hphotos-ak-snc6/s480x480/10581_10151177885380827_507503979_n.jpg%5Dhttp://sphotos-g.ak.fbcdn.net/hphotos-ak-snc6/s480x480/10581_10151177885380827_507503979_n.jpg)
(http://photos-a.ak.fbcdn.net/hphotos-ak-ash4/c0.81.720.478/s320x320/251388_10151177724745827_660325636_n.jpg%5Dhttp://photos-a.ak.fbcdn.net/hphotos-ak-ash4/c0.81.720.478/s320x320/251388_10151177724745827_660325636_n.jpg)
Fixed it for you.
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on September 29, 2012, 05:11:29 PM
I think a standard Fj weighs about 250kg wet   ( oil/ fuel ) ,
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 30, 2012, 01:24:59 AM
(http://[url=http://photos-a.ak.fbcdn.net/hphotos-ak-ash4/s720x720/251388_10151177724745827_660325636_n.jpg%5Dhttp://photos-a.ak.fbcdn.net/hphotos-ak-ash4/s720x720/251388_10151177724745827_660325636_n.jpg%5B/url%5D)
thanks the second image was cropped for some reason. Here is full image.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on September 30, 2012, 07:58:29 AM
(http://[url=http://photos-a.ak.fbcdn.net/hphotos-ak-ash4/s720x720/251388_10151177724745827_660325636_n.jpg%5Dhttp://photos-a.ak.fbcdn.net/hphotos-ak-ash4/s720x720/251388_10151177724745827_660325636_n.jpg%5B/url%5D)
Title: Re: fj1200 turbo "thug"
Post by: FJmonkey on September 30, 2012, 09:11:01 AM
Quote from: backstreetheros on September 30, 2012, 07:58:29 AM
(http://photos-a.ak.fbcdn.net/hphotos-ak-ash4/s720x720/251388_10151177724745827_660325636_n.jpg)
I am gonna have start charging you for my "fix it for you" service.....

If you want to see the code that works for displaying your photos, click on the Reply With Quote just above this post. It will show you the code. Pay attention to the "[img ] and [/img ] I added a space to void the code. You don't need to add the [url ] codes unless you want the file to be a Hyperlink.

Looks like 2 batteries will fit, add an electric motor and you can limp home on it if you run out of gas.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 02, 2012, 09:59:46 AM
haha thanks for the corrections, i was uploading the pictures from my phone and clearly i messed up the code.
i will be trying to fit dynatech 2000 ignition box into this box too, the only place i have left to mount it is on the left had side of the bike (where the engine drive sprocket is) hopefully this and the oil cooler on that side will counterbalance some of the weight of the turbo off to the right as the bike is slightly weighted to that side.
i've decided i need to start getting rid of stuff i dont need/use as im low on storage space so all the proceeds of this will go towards the shiney bits i have to buy for the bike as i've already smashed my budget. (although paypal is now holding my money for 21 days so can't buy my ignition just yet!)
need to make about £130 for the bits i need from rpm racing
£230 for dynatechs ignition for the bike

what weight of oil do people reccomend for this motor?

and am i correct in saying...
as i'm increasing the overall volume of oil in the engine (by adding two huge oil coolers and lots of pipe) i will need to add that volume of oil extra into the engines sump?
if i remember correctly it was 2000cc for the engine as standard...
so if i filled the standard oil cooler and pipes (upside down) with oil  and tipped it into a measuring jug then deducted that ammount from 2000cc
then filled my two new oil coolers and pipework and measured again then added that ammount to the answer of above...
i would still have the correct amount of oil in the engine when it actually pumps around the oil coolers?
dont perticularly want to run the engine dry of oil.
Title: Re: fj1200 turbo "thug"
Post by: FJmonkey on October 02, 2012, 10:34:46 AM
Quote from: backstreetheros on October 02, 2012, 09:59:46 AM
what weight of oil do people reccomend for this motor?

Oh shit!!! He asked THE OIL question.  :dash1:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 02, 2012, 10:53:13 AM
is that a touchy subject on this forum aswell as others?
(at least i didnt ask if i could use ATF as Fork oil!!)

got a bit carried away on RPM's website and placed my order!
i've ordered...
two oil pan fittings back to unions so i can ditch the tiny oil cooler on the front of the engine.
one spin on oil filter adapter (not for the filter) but so i can fit the mocal sandwich plate oil cooler adapter i purchased a few days ago
also one oil galley tapped adaptor so i can run an oil temperature gauge (as i dont have any instruments)

total was $169.37 including $44.70 of shipping to England
(if your in England... £104 with £27 postage) :good:

cheap if you ask me... pretty excited now. :yahoo:
as soon as paypal pull their finger out i'll buy the ignition from dynatech and see if i can make this bike run!

again... if you own an FJ you seriously need to look at their website!
http://www.rpmracingca.com/ (http://www.rpmracingca.com/)

will be interesting to see how long it takes to arrive... more pictures when it arrives!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 02, 2012, 11:48:46 AM
(http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash4/250185_10151182164545827_660431389_n.jpg)

(http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/548767_10151182165155827_557805494_n.jpg)

(http://sphotos-a.ak.fbcdn.net/hphotos-ak-prn1/35441_10151182165735827_1582306834_n.jpg)

hopefully i'll be able to scratch these bits up a bit or something so they ain't so shiney!!



another dreaded oil question... does anyone know standard oil pressure on a FJ12? (the reason i ask is i need to know what range oil pressure gauge to find)
:good2:
Title: Re: fj1200 turbo "thug"
Post by: FJmonkey on October 02, 2012, 11:54:18 AM
Quote from: backstreetheros on October 02, 2012, 11:48:46 AM
hopefully i'll be able to scratch these bits up a bit or something so they ain't so shiney!!

another dreaded oil question... does anyone know standard oil pressure on a FJ12? (the reason i ask is i need to know what range oil pressure gauge to find)
:good2:
Careful where you alter the surface condition on the spin-on plate, that is a sealing surface.
Title: Re: fj1200 turbo "thug"
Post by: Pat Conlon on October 02, 2012, 01:13:45 PM
Quote from: backstreetheros on September 07, 2012, 08:41:59 AM


(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/561480_10151147402545827_1522654964_n.jpg)


I've been meaning to ask..... DavidR, Randy and others....with what you know about the Mikuni CV36BS carbs is it ok to pressurize them with forced induction? Any problems with the vent passages not being under atmospheric pressure or the vacuum slide functions?
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on October 02, 2012, 04:27:19 PM
interested in finding about your carb manifold , also the silicon boots you joined the carbs to it with,  :good2:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 03, 2012, 12:25:38 AM
Id also be interested to find out if anyone has any theoretical issue with the carbs.
The plenum is made of aluminum. Was originally made for a gsxr1300 aparantly. Has 4 pipes coming off the plenum, two to pressurise the diaphram tops and two to pressurise the float bowls. The rubber boots are just some cut up silicone hose that came with the plenum.
Im actually using the plenum upside down as it was intended to be up the other way.
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on October 03, 2012, 12:45:32 AM
just one issue you may have , how will you synchronize the carbs
Title: Re: fj1200 turbo "thug"
Post by: miked on October 03, 2012, 03:57:56 AM
Quote from: fj11.5 on October 03, 2012, 12:45:32 AM
just one issue you may have , how will you synchronize the carbs

Hey Rod, I might be not thinking this through enough, but what's the difference ? The gauge/manometer connects to the engine side anyway, and he still has the ports there to connect them to. Adjusting the linkages between the carbs isn't a problem. Or are you talking about the forced induction being an issue.
Sorry if it seems like a stupid question, but I like to learn "new stuff" I have never played with forced induction other than on massive HP diesel mining machines.

Cheers

Mike
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on October 03, 2012, 07:00:14 AM
Well im probably wrong mate,  but going by the post about what the plenum chamber was built for dousnt seem the usual synch tubes are there, can see two that could be ,, speaking of forced induction ive wondered the same myself before,  if fj,s could have hoses fitted into an airbox and directed  forwards into the airflow like early zxr,s had,  dam things nearly suck the milk from your tea if you stood in front of them when going
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 03, 2012, 08:01:36 AM
can you explain what you mean by synch tubes?
if you mean pitot tubes then there is 4 of them from the plenum.
the carbs could be syncronised with the plenum removed as i imagine the turbo (with the air side disconnected) will have very little exhaust flow restriction.
i won't be doing any syncronising myself, i'll get my friendly bike mechanic to do that for me as he has a fjr1300 with NOS and he's fairly good with setting up bikes where as my knowledge of fine tuning carbs is not up to scratch. nor do i have the equipment.

the only issue i have left is getting my ass into gear and doing some work on it and regulating my fuel pressure. i will worry about fuelling when after i get the oil cooling and ignition sorted out.


Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 12, 2012, 12:31:37 PM
recieved some shiney bits today... thanks randy!
(http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash4/229973_10151196906675827_1467977488_n.jpg)


got time the other day to cut the standard fj oil cooler and brackets off the frame to make space for my 15 row subaru impreza oil cooler.
(http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/528614_10151194020820827_560931499_n.jpg)

still havnt managed to get the bike out of the shed yet as been busy with work but got alot of mounts and braces to make next time i get the welder out.
will mount the oil coolers and ammo box and brace the footpeg braces as they dont look strong enough to me.
i will get there eventually...
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 12, 2012, 06:44:14 PM
got a bit carried away after recieving some new parts from randy and spent my whole evening on the bike... completed the following
extended lock stops to stop steering travel hitting all my pipework and turbo.
braced the footpegs with a tubular brace
made and mounted the oil cooler brackets to replace the small FJ oil cooler with a 15 row impreza one.
made an exhaust bracket to stiffen up my side exit and take some of the load off the exhaust studs.
cut off the pillion footpeg brackets
fitted another set of brackets for another 15 row impreza oil cooler on the rear to cool the turbo oil system.
mounted my oil pump and bracket to the bike.
fitted my ammo box to the side of the bikes and welded on brackets to hold it stiff so the battery and ignition can be fitted.
found out some nyloc nuts to hold my petrol tank on.
and made a bracket/bolt-peice to hold the rear caliper mount to the frame.

all in all an extremely productive evening!
although i can feel my forhead is burnt from tacking things in place!

had to move the bike out of its usual shed for good now as it no longer fits through a doorway with the new lock stops and ammo box.
will do the spin on filter conversion tomorrow and fit the bits i got from RPM tomorrow aswell as take a load of pictures to post
was going to tonight but the light was poor in the workshop for taking pictures.
making progress!  :dance:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 14, 2012, 04:34:24 PM
(http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash3/578562_10151198299505827_1980685105_n.jpg)

(http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/46323_10151198123700827_1444263285_n.jpg)

(http://sphotos-a.ak.fbcdn.net/hphotos-ak-prn1/523758_10151198186530827_456174738_n.jpg)

(http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash4/314213_10151198304395827_1065926816_n.jpg)

as you may be able to see the ammo box covers the kickstand making it only possible to use by getting off the bike and putting your hand under... this was crap so we bent and welded a spanner to follow the angle of the ammo box and now can be used to kick the stand out with your foot. plus it looks funny.
i'll get pictures of that up soon.
also mounted an oil temperature gauge to the frame above the tank and fitted randys tapped sender plug (had to space off my master cylinder as it touched)

the bike is now evenly weighted due to the battery counterbalancing the turbo.

i'll get some more pictures up soon of progress.
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on October 14, 2012, 04:59:52 PM
and that is how a chopper should be built , not with off the shelf parts like certain "custom builders" use, about all they custom build are tanks and gaurds, maybe exhaust systems , , what colour you going to paint this beasty, , just do the wheels and engine black and clear coat the rest as it is  :good2:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 15, 2012, 12:39:19 AM
the bike is already painted...
its a flat rust colour with gold glitter in it made to look crappy. i've just gone for the approach of not painting anything atall, not even welds.
later on i might paint it nato green with some military stencils but at the moment i'm liking the look.
it will certainly turn heads!

still a way off yet though. need another good weekend on it and shouldnt be too far off then...
still need to order my igniton!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 23, 2012, 04:48:27 PM
done a bit more on the bike recently and managed to get most of the brakes done. converted them back to individual use and linled the rears together
ordered my dyna 2000 igniton today and coils
also ordered the tank sealer which is impossible to find in the parts shops!
also ordered two mk2 spitfire switch panels for the pumps and ignition.
went to my local ish bike breakers for a starter relay and they gave me some brake pipes and bits!
will definatly need some form of kill switch.
struggling to findanother mocal 15 row oil cooler!
need to make something as a brake fluid resivoir too.
will get some more pictures up soon.
start date is approaching fast!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 23, 2012, 05:03:07 PM
(http://[url=http://photos-b.ak.fbcdn.net/hphotos-ak-prn1/s720x720/37799_10151198181860827_1406613578_n.jpg%5Dhttp://photos-b.ak.fbcdn.net/hphotos-ak-prn1/s720x720/37799_10151198181860827_1406613578_n.jpg%5B/url%5D)
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 23, 2012, 05:13:15 PM
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/66265_10151203842530827_1667265028_n.jpg] (http://[url)
Title: Re: fj1200 turbo "thug"
Post by: minitruckeratheart on October 23, 2012, 09:00:29 PM
I just read this thread, nice lookin bike. cant wait to see what itll do when shes running!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on October 24, 2012, 05:32:04 AM
ordered a malpassi petrol king fuel pressure regulator today. would be much happier finding these parts off oyhrr vehivles but its proving that ebay is the only place for such specialist parts.
eagerly awaiting the postman now before i can continue!
i will get a video of first start attempt and a run through of the starting procedure to prime the turbo oil!
to be continued...
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 04, 2012, 07:19:14 AM
not forgotten about this project... just been busy with work...
although i have been doing a bit of shopping ready for the big day.
(http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash4/317163_10151232402535827_1650220573_n.jpg)

i've got...
castrol power 1 for the bike
castrol magnatec 10w-40 for the turbo system
some cheap ass brake fluid to get the brakes filled and working
couldnt find another matching 15 row mocal oil cooler so got this 16 row one from APS. should be able to fettle it into my brackets.
PETSEAL petrol tank sealer as the tank inside isnt the cleanest.
malpassi petrol king fuel pressure regulator with boost sensitive flow
4 NGK spark plugs. (i wanted better ones but these will do just to get it started and replace at a later date.
oil filter so i can fit the spin on filter adapter.
fuel pressure guage with T peice and 8mm hose tails
two switch panels with starter buttons
8mm banjo bolt to replace the 4mm oil feed to the turbo which i dont like the look of.

got a letter from parcelforce today saying i now have to pay customs duty on my igniton because it comes from america...
thats great seeing as i've now paid £145 (232 USD) in postage alone!! this better be good :dash2:

should have the ignition in a few days so will take a day off work and get some progress made!
Title: Re: fj1200 turbo "thug"
Post by: rktmanfj on November 04, 2012, 08:38:49 AM
Quote from: backstreetheros on October 23, 2012, 05:13:15 PM
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/66265_10151203842530827_1667265028_n.jpg] [url]http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/66265_10151203842530827_1667265028_n.jpg (http://[url) [/url]



(http://i643.photobucket.com/albums/uu159/rktmanfj/66265_10151203842530827_1667265028_n_zps422935bc.jpg)
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 07, 2012, 04:52:56 PM
got a bit carried away with myself yesterday as my dyna 2000 ignition and coils came in the post...
rushed to get the bike out and fitted the ignition and coils but had no brackets for the coils so thought i'd rush at work and get a few hours in today.
after running late from work i was determined to get something done on the bike so cleared a space in the workshop and made a start...
made brackets for the coils to hang up tight under the fuel tank.
made a bracket to hold my fuel pressure regulator
fitted my two oil coolers into the brackets i previously made on the frame
welded the boost gauge bracket on the frame and mounted that.
i did the tank sealer yesterday but snapped the petrol tap off by accident so have ordered a new one. wont hurt to have new.
i finished the ignition wiring too and fitted the new spark plugs.
after i stood back for a second i thought... this thing might just fire up?!
so i put a funnel on the carb feed and tipped a bit of petrol in (bypassing the fuel pump and regulator)
tipped some oil into the turbo just to lube it up a bit
connected up my ignition switch live to the battery
pushed the choke rod, touched the starter wire on the battery...
cranks over once then fires to my amazement!! i thought awesome its ticking over!!  :lol: :good:
then it cuts out... so choke off... fires again on the button, ticks over lovely, no strange noises
can't believe i got it all right first time! sounds like a complete animal!!
once i managed to calm myself down a bit i carried on and fitted randys spin on oil filter adapter which was easy
bike back in the shed now... once i get the oil lines finished i'll get a video and post it up.  :yahoo:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 09, 2012, 12:21:30 PM
following randys advice i ditched the huge oil cooler lines i previously bought...
went to my local engineering shop today and they made me up two an-6 female to male hoses for a reasonable £53.00
they are PARKER hydraulic hoses.
then i went to bredy agricentre (tractor shop) and they supplied me with two an-10 to an-6 reducers and a Male to female an-6 elbow.
all fits well on the bike. i had the return hose to the engine made extra long so i could route it well away from the exhaust pipes.
i'll try get some pictures up tomorrow.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 10, 2012, 08:44:12 AM
finally got a video uploaded.
with the plenum removed for tesing...
fj1200 turbo first start (http://www.youtube.com/watch?v=2LvaLoH31J8#)
Title: Re: fj1200 turbo "thug"
Post by: FJmonkey on November 10, 2012, 09:04:03 AM
The beast is alive!!!! So far so good.
Title: Re: fj1200 turbo "thug"
Post by: Dan Filetti on November 10, 2012, 10:17:55 PM
Excellent!  Glad to see this Fraken-bike fire up!  The sound is excellent.  Is that the turbo spinning sound I hear?

Dan 
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 11, 2012, 11:48:51 AM
yeah the turbo seems to spool up nicely in the middle of rev range.
i did find out as soon as the oil pressure builds up it fires the clutch push rod (including all your new oil) a foot out the side of the engine... no wonder i couldnt find the clutch slave cylinder... i dont have one!! anyone got one for sale?
ive booked up half of my 4 day bike test for next week as i wont be able to ride it without it!
tank is done and im working my way through the fuel lines...
my oil pump puts out way more pressure than my turbo can handle so have to make a bypass to stop the pipes exploding.
i also need to find a suitable boost pressure switch to trigger the ignition retard under boost. a handy feature of my dyna 2000 ignition!
more progress soon...
Title: Re: fj1200 turbo "thug"
Post by: Havoc on November 11, 2012, 01:56:55 PM
I also had a 'bugger', 'starting the motor up without a clutch slave' moment. On my nieghbours newly laid block paved drive, a nice 12' line of oil, she wouldn't let me use my power jet cleaner either, 'cos of distubing the sand beneith the blocks. Hand's and knees with a scrubbing brush. It was at that precise moment I decided that the FJ oil pump pressure would be fine to feed a plain bearing turbo and an aux head cooler. Got a spare slave by the way, where are you?
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 11, 2012, 03:33:31 PM
haha i know exactly what you means by "bugger!"
have you increased the amount of oil in your motor? seeing as more is being taken away from the sump while running?
this was my main concern as to turbo oil cooling and my huge oil cooler.
hence why i went for a completely seperate cooling system. and the turbo i used is standard journal bearing subaru impreza so easily available for £40 if i screw it up!!
im in England.
how much do you want for the slave? where are you with regards to postage?  :good2:
i was gutted to see i didnt have one!!!
luckily where i started the bike it didnt matter too much about oil spillage!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 11, 2012, 03:40:38 PM
nottingham sorry... i clearly didnt see your profile thing...
im in west dorset, bridport to be precise.
how much do you want for it? i don't have any suitable swapping items really unless you need anything plumbing.
we will one day have to have a drag race you know that you'll definatly win!!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 11, 2012, 05:07:24 PM
here is a picture where you can see the two oil coolers.
if you look closely you can see the pipes i had made up for the front oil cooler (inc the extra long one to avoid the exhaust manifold)
once all the brakes are done and working, clutch and the turbo oiling system fine tuned i'll take it to my bike shop to get a chain fitted so we can see what it rides like. i'll try get a video of that too.
still a way off but would like the bike to be on the road by next summer so i can take it to a few shows!..
i might do a completely seperate write up on getting it through an MOT!!  :sarcastic:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 11, 2012, 05:07:42 PM
(http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash3/534088_10151243669530827_298310233_n.jpg)
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 12, 2012, 01:08:36 PM
spent the day doing the bike today...
one big step forwards and one giant leap backwards to report!
i managed to get the brakes working after struggling to bleed them and then getting a power bleeder from a friend to complete the job.
a friendly mechanic i know gave me a rear brake resivoir as i couldnt find one anywhere in town and he replaced his, no idea what bike its from.
after half of the day of bleeding and unsticking things i got it all working correctly  :good2:
after this i thought i'd make up the bypass for my turbo oil cooling system.
did this, filled it up and eagerly tested it... its bullshit.
the pump was too powerful before and now just dies on the thermal overload as too much resistance trying to move thick oil.
i now have to drain all of this and rip the lot out.
i suppose this is what you get for trying to do something different.
i think the solution is to get another oil galley plug from randy, use this to take a oil feed to the turbo and then pipe it back down into the clutch cover as a return.
i could have kicked the bike over when the oiling didnt work haha  :dash2:
oh well live and learn...
i'll have to buy some new bits and rip out all the crap i've done aswell.
got a load of stuff for sale now if anyone needs it?
Title: Re: fj1200 turbo "thug"
Post by: musicman on November 12, 2012, 10:08:15 PM
On the turbo, you'll probably want to run engine oil for that side of things rather than a separate system. Turbo's don't like a lot of oil, on my Camaro the last setup I used was a 3an feed line and a 10an drain. You want a good quick gravity drain, no sharp corners, no 90* angles, etc. And you want the drain to be above oil level usually. Also I'd contact the turbo manufacturer, some turbos need a restricter in the feed line, otherwise they puke past the seals and you get a nice mess. Never turbocharged a bike before, though it would be fun to do someday. You might also think about ditching the 4 carbs in favor of a single large one pre-turbo mounted at the inlet. Something like a weber 2 barrel or something, might be worth looking into.
Title: Re: fj1200 turbo "thug"
Post by: Havoc on November 13, 2012, 12:39:40 AM
I agree with Musicman, just drill and tape either of the gallery plugs left or right side of the motor to take brake line banjo bolt, see my head cooler feed. Feed using some braided brake line, about 2-3mm internal diameter then drain back in using a larger diameter line. You turbo is well high so gravity feed return will work well. If you want to go a more expensive route Pirtek do adaper plugs to fit Earls type lines though you'd want to restrict flow somw what, less important though with your plain bearing turbo than a Ball Bearing turbo. I'll not have an oppertunity to get up the shed to finf the spare slave until the weekend I'm afraid, stoopid busy at work this week and no  power in there for light.

(http://i214.photobucket.com/albums/cc122/cabletietom/20120726_181114.jpg)
Title: Re: fj1200 turbo "thug"
Post by: Havoc on November 13, 2012, 03:11:46 AM
Disagree about going draw through though, stick with the blow through, works fine with CV's if the pitot is right. Early XJR slaves should fit and are easier to source if I can't find my spare.
Title: Re: fj1200 turbo "thug"
Post by: fj11.5 on November 13, 2012, 04:05:32 AM
Big katana fan, and i must shay  thatss an awesome kat  ,,, and she isn't even  finished, fj engine :good2:  looks at home
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 13, 2012, 11:25:49 AM
i am sticking with blow through for rideability. it'll just ride like a normal fj before the turbo spools (almost!)
the turbo im using already has a restrictor built in hence why my seperate system didnt work.
i was bidding on some fj clutch and oil pump covers on ebay with windows but i wasnt willing to pay that much! fair play to whoever won them!
i think i will tap the galley plug myself as this will be alot faster than ordering randys (postage takes ages from america!)
where did you put your drain into havoc? i was almost tempted to just tap it into the oil filler cap?! saves drilling holes!
Title: Re: fj1200 turbo "thug"
Post by: Havoc on November 13, 2012, 12:31:11 PM
I welded a boss for a fixing into the sump, I've got a pump assissed drain though as I feel my turbo is just slightly too low. I'd gravity feed yours back above the oil height, into the oil filler seems as good a place as any. You're not 'Falmouthgrove' by any chance are you, sold my sidewinder copy pipe to someone down your way a while back and I noticed a bid on my DYNA2000 from the same name? It's the long forks got me thinking. :good:
Title: Re: fj1200 turbo "thug"
Post by: racerrad8 on November 13, 2012, 02:38:36 PM
Quote from: backstreetheros on November 13, 2012, 11:25:49 AM
i think i will tap the galley plug myself as this will be alot faster than ordering randys (postage takes ages from america!)
where did you put your drain into havoc? i was almost tempted to just tap it into the oil filler cap?! saves drilling holes!

Be careful tapping the stock galley plug. They are cast aluminum and I have seen several failures of those plugs when they are tapped as there is not much material to work with. The drilling & tapping takes away so much material the plugs can crack/split and then it pumps all the oil on the ground and under your rear tire.

If you order with USPS priority service you will have it in about 7 days.

If you still need that slave cylinder I have them in both colors, I can add the galley plug as well.

Do you know if you have the fine or course thread oil fill cap? If it is the fine one I have a cap that I removed from a customers engine years ago that has a 5/8" nipple pressed into it. I will throw that in the box as well.

Randy - RPM
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 13, 2012, 03:09:32 PM
Quote from: Havoc on November 13, 2012, 12:31:11 PM
I welded a boss for a fixing into the sump, I've got a pump assissed drain though as I feel my turbo is just slightly too low. I'd gravity feed yours back above the oil height, into the oil filler seems as good a place as any. You're not 'Falmouthgrove' by any chance are you, sold my sidewinder copy pipe to someone down your way a while back and I noticed a bid on my DYNA2000 from the same name? It's the long forks got me thinking. :good:
i'm not falmouthgrove i'm sorry to say.
i already purchased my dyna 2000 from ebay.
what pump are you using as an oil scavenge pump? the brass gear pump i bought for mine is up for sale as useless to me now.


[/quote]


If you order with USPS priority service you will have it in about 7 days.

If you still need that slave cylinder I have them in both colors, I can add the galley plug as well.

Do you know if you have the fine or course thread oil fill cap? If it is the fine one I have a cap that I removed from a customers engine years ago that has a 5/8" nipple pressed into it. I will throw that in the box as well.

Randy - RPM
[/quote]

i'll make an order!.
i think mine is a fine thread, don't know what a corse looks like to compare?
definatly have a black slave cylinder as silver wouldnt look right.


i purchased the new oil line i need to take from the front tapping in the engine (yet to order) to the turbo.
i have decided to do this in AN-4 and not add an aditional oil cooler for the turbo seeing as i have that huge 16 row one on the engine anyway.

randy do you suggest i slightly overfill the oil to compensate for the oil in the bigger cooler and in the turbo or just make sure its at the top level?
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 13, 2012, 03:20:10 PM
just placed my order for oil galley plug and a black slave cylinder. after ordering it... i thought... i dont have the bolts for the slave either...
dont suppose you have the bolts too randy? happy to pay for them. pm me and i'll make a balance transfer.
many thanks.
Title: Re: fj1200 turbo "thug"
Post by: Havoc on November 13, 2012, 04:03:24 PM
Agree with Randy, the gallery blanks are made of monkey metal, you've made the correct choice. After consideration I do recall one snapping off the thread during the rebuild. I'm using an electric pump to scavenge the turbo, will be turned off separately a couple of seconds after shutting the motor down.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 13, 2012, 04:34:08 PM
just aswell do it properly...
once again i'm waiting on the postman haha. he says he hates me! i get at least 3 parcels a day and he doesnt like carrying them up my drive  :lol:
poor bloke.

i have realised i'm going to end up with a big space behind the engine seeing as i crammed everything upfront to make it all fit and now everything behind the engine i'm going to chuck out.
i'm sure something interesting will turn up to go in there!
might just have to be another ammo box so i can take a packed lunch for when it breaks down and the misses has to come and get me in the van!
one bonus of having big vans... :good2:

i confronted my MOT tester yesterday with a few questions as to having the bike with no lights...
for him to pass it he's said...
i need a reflector (i bought two of those small stick on ones that i will stick on the furthest rear of the frame)
a full size number plate.
an electric horn.

in answer to my questions...
i dont need a front mud guard.
i dont need any lights. front or back, indicators or even a brake light.
i dont need mirrors.
i dont need a chain guard.
i dont need a speedo.
and my exhaust is fine!
(aparantly a speedo and a mud guard is a legal requirement but not needed to pass an MOT?)
i'm not going to fit a mudguard anyway.

with regards to brake lights... i will fit one after the MOT test just for safety, but no other lights.


Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 15, 2012, 07:42:38 AM
got my oil line fittings in the post today to take a feed from the engine oil galley to the turbo
3 meters of hose so i dont come up short.
an-4 to 10 x 1.25 adapter to go into turbo oil feed
an-4 to 1/8 npt for randys oil galley plug.
two an-4 to hose 90 degree bends.

(http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash4/188558_10151248687840827_1344847724_n.jpg)

just waiting on my parcel from randy now...
the misses birthday today so i should really do something with her and not play with my bike...  :shok:

Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on November 20, 2012, 04:46:48 PM
I think ive sent you a PM,but just in case it hasnt worked and you need things relating to the 50 quid offer (egay)feel free to PM me.
This is still one of my fave FJ builds,along with Havoc's. The brits rule!!! lol.
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on November 21, 2012, 03:44:31 AM
Can i quickly share a couple of pics to show you a bike being built by a good friend of mine,who was going turbo,but decided to just go normally aspirated.
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/chopper%20stuff/12813_448367405200489_1350680142_n.jpg)
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/chopper%20stuff/389557_446247405412489_565469689_n-1.jpg)

This show's the brits make the craziest stuff when it comes to wacky stuff with FJ's. :lol:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 21, 2012, 08:58:06 AM
thats a real pretty frame!

just recieved my parcel from randy.
got my slave cylinder and oil connection for the turbo feed.
also a massive thanks to randy for the tapped oil cap and the spare bolt.
i'm very dissapointed to say this oil cap will not fit my fj... fuck! :mad: :ireful:

(http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash4/396603_10151257629460827_1105698350_n.jpg)

i will have to have something made i think.

i went to fix someones central heating system yesterday who has had a lot of problems with it...
finally found the cure and fixed it to both of our delight.
he is a very avid motorcyclist and has 2 bikes he rides, one for his misses and one chopper he's building.
all of which have their own bedroom in his house!! a lovely chap and a damn good laugh.

the bike is a GSXR 750 slingshot motor in a Hard-Up-Choppers frame, USD forks, a real pretty bike.
after having a few words with him about his mid position valve being broken on his central heating system i bought the bike off him...
not that i really needed another project but it was too nice not to!
i'll get some pictures up soon.
this one will be a bit prettier than the fj as its already been booked in with a friend that ownes a paint shop to do a full candy/pearl white spray...

i could do with 2 weekends in a week if anyone can make that possible?? lol...

i've finished early today to get these turbo lines done but got a bit stuck without the cap! bugger...
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 21, 2012, 11:23:59 AM
spent the last hour or so doing these bloody turbo lines...
all my remote oiling system for the turbo is now in the skip.
made up the new oil line to the turbo and was quite pleased with my efforts.
the braided hose and AN fittings almost looked too good to put on the thug.

was just about to fit this lovely hose when it fell apart in my hand... maybe i tightened it too much?!
obviously im not used to these limp wristed hose fitters fittings...
(http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/178967_10151257801330827_906258207_n.jpg)

so i decided i'd give up after that as i don't have anymore AN fittings to fix it  :ireful:
went to fit my clutch slave cylinder and was pleasantly confronted with another issue...
you can't fit a clutch slave cylinder without a engine side sprocket cover?!?!!!!
i wish i had taken the FJ apart in the first place to remove this donor engine.

hopefully i shouldnt have any of these problems with the GSXR chop.
the seat is already mounted, just needs springs (its has padding too!)
its got a propper electrics box under the seat with standard GSXR ignition.
the forks don't have any stupid antidive holes in them to cap off like the fjt
all the controls are finished as well as all brake lines bar one are done
it needs... wiring properly.
paint.
exhausts.
rear brake caliper tourque bar making.
a chain.
might go for another daytime MOT on it like the fjt
pictures soon. :dance:
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on November 22, 2012, 10:31:15 AM
As a fellow HUC owner,I found the chain run,with std sized sprockets,allows the chain to hit the battery box. You cant use donor exhausts,as the front down tubes of the frame are badly positioned,and watch for them being very very low!! I know,as Ive 3!!! Im chopping the front downtubes out of mine,rebending some new tubes and welding them back in. Im using a Bandit frame as the template for the tubes. Its a bit of a bind,but it will give me a nicer exhaust fit. Ive just made some turbo headers for a HUC,and they had to be  extended out from the engine to make fit. They are cheap bases for a build,but i hate them now!!! lol.
I bought (as you know)a frame for an FJ12,and i bought a complete fj12 as a donor,but have had a change of heart. But good luck anyway! lol. Give me a shout if you need a window cover thing. :good2:

turbo huc
(http://)(http://i596.photobucket.com/albums/tt50/lindarobjones/chopper%20stuff/9ED019BE-DA26-44AB-8D67-DC8B9A318F9D-10093-0000083BE688DF8B.jpg)
Title: Re: fj1200 turbo "thug"
Post by: Havoc on November 22, 2012, 12:56:39 PM
Loads of covers on the bay. This is the cheapest

http://www.ebay.co.uk/itm/YAMAHA-FJ-1200-FRONT-SPROCKET-COVER-/190752387921?pt=UK_Motorcycle_Parts&hash=item2c69ba7351 (http://www.ebay.co.uk/itm/YAMAHA-FJ-1200-FRONT-SPROCKET-COVER-/190752387921?pt=UK_Motorcycle_Parts&hash=item2c69ba7351)

Havoc
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 22, 2012, 02:43:19 PM
nice to hear from another HUC owner!
i've already spotted the standard exhaust issue... im either going to buy a set of headers on ebay and chop them about, being stainless... my local xar tuning place will have to do it.
or... just buy HUC's exhausts for £320 delivered... job done.

i've just bought a sprocket cover on ebay so will do the clutch when that arrives... anyone know what thread pitch the slave cylinder banjos are? im short of one.

also anyone selling anti-dive blanking plates contact me!!

still not done anymore on the fj as the oil line screwed me right up, i might just drill a hole in my oil cap and press a tail in it for the return line.

my HUC doesnt have a battery box fitted yet. i was going to mount one on the right hand side of the frame and use it as a bracket to hold the rear brake resivoir.
no turbos on this one i think. i'm quite keen on the wrapped exhausts look too so might have a go at that.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 25, 2012, 05:39:42 PM
right progress...
i managed to get the AN oil line fitting from hosefittingsUK on ebay, and finished that oil line.
i pressed the pipe tail out of the aluminum oil cap randy sent me (cheers again) and machined out my resin one so it would fit snugly in there...
after about 10 trial fitments (i could almost push it all the way through by hand) and i decided to press it in there... using locktite as lubricant.
my resin plug shattered as i obviously didnt machine enough out! bugger. (i've had alot of "bugger" moments on this build!)
now i need to find an aluminum course thread oil cap to set to work on...

i've ordered the front sprocket cover for the fjt.
i have been looking for ideas for speedos and i've spotted this...
(http://www.flickr.com/photos/jefflynne/4019189423/in/photostream/)

(http://www.flickr.com/photos/jefflynne/4019186293/in/photostream/)

where would i get two of these? just aswell have one on the fjt and the gsxr!
i'd prefer to stay away from the streetfighter style vapor ones.

not that anyone on here is interested, i bought a set of GSXR headers to go on my GSXR chop but they will need chopping about all over the place to make fit the low slung frame, luckily i know a lad that works in a car modifying place opposite my local plumbers merchants! he's going to give me a price for the whole job then i can leave the bike there so i dont have two choppers taking up all my space. the GSXR chop is already booked into the paint shop at the end of december so i better hurry up and get all the welding done on the frame! (candy and pearl white frame, tank and rear mudguard should be pretty!)

i've also ordered a boost pressure switch for the fjt that is normally open circuit. i had to special order this from Wizards-of-nos as i couldnt find it anywhere else. i will use this to trigger the ignition retard from my dyna 2000 ignition. and luckily... the brass 42mm-42mm-1/2bsp "T"  i used for the dump valve happens to be 1/2"bsp thread inside, so i can thread a T into it and have the dump valve and the boost pressure switch (which is male 1/8bsp) in the same place. nice job  :good:

once i get these faffy bits done i will have to mount my fuel pump properly and run all the fuel lines.
then i've got a whole lot of wiring to do.
i've bought some small aftermarket ignition switches for both bikes so they can have keys ( a bit safer )

getting a bit stressed with running a plumbing business, building a turbo chopper,building a GSXR chopper, restoring and modifying a mercury outboard and having a misses all at once!  :bomb:

i palmed my outboard off on my painter and told him to take a few months to repaint it all (keeps it out of my way for a few months!)
once the GSXR frame is complete that can go to him too so one less thing to worry about...
the misses... unfortunatly i can only send her to the salon  :rofl2:




Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on November 25, 2012, 06:09:35 PM
this is how i did the oil plug...

(http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash4/s480x480/487154_10151264305900827_1669458013_n.jpg)

i used some plumbing fittings and a vice to press out the tail from the aluminum oil cap.

(http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/15992_10151264319355827_1255906365_n.jpg)


this is what it should have looked like...

(http://sphotos-c.ak.fbcdn.net/hphotos-ak-prn1/542727_10151264324880827_133703882_n.jpg)

and this is what it actually looks like...

(http://sphotos-c.ak.fbcdn.net/hphotos-ak-prn1/148158_10151264335275827_782793003_n.jpg)

"bugger"
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on December 01, 2012, 05:32:45 AM
I forgot to mention i think,i made the turbo headers for the turbo huc. Ive still got the welding jig for them too.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on December 03, 2012, 03:11:36 PM
quick few pictures here. not really made much progress as waiting for my aluminum oil cap to have a pipe welded to it! wish the engineers would hurry!
this is a quick snapshot of the gsxr 750 im building alongside the fjt.
(http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash3/27987_10151276088250827_1242625792_n.jpg)

much prettier than the fjt too!!

i got my chain from my local bike shop with a shed load of other bits i've been buying!
luckily the chain came in a 25ft roll as i needed a much bigger length than standard...
the guy welding my stainless exhaust told me he needs the chain before he can do the exhaust to make sure it all misses.
the leftovers will make a perfect chain for my fjt! nice job!! cheap chains all round!
i'll try to stop posting pictures of this bike as im sure no-one cares as it doesnt have any fj bits  :shok: :rofl2:

(http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/47289_10151276091110827_2087295035_n.jpg)

i'll do another progress report on the yamaha when i get the oil cap back as thats holding me up!
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on December 03, 2012, 04:38:46 PM
Looking good. I had to slice my leccy box down,as the chain was hitting it. So check before it goes for paint etc. :biggrin:
Ive lost all interest in mine at the moment,but its nice to see somebody else enjoying a HUC. :biggrin:
Im going back to my roots,oldskool gsx1260efe (gs1150) and Ive plans for one of my FJ12's.
Title: Re: fj1200 turbo "thug"
Post by: racerman_27410 on December 03, 2012, 04:57:17 PM
I'm not sure i would be using cheap chain in this application..... a stock FJ is capable of stretching a chain pretty quickly.

Now add in the turbo.......

the though of that chain breaking and coming back on my leg would be enough for me to spring for some EK ZZZ chain.


Last time i experienced pain it was very real!



KOokaloo!

Frank
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on December 03, 2012, 05:09:16 PM
my electrics box has a nice notch already cut out of it, thanks to the previous owner!
just finishing off the frame and doing a full build before paint so nothing is missed.
i'm back onto making up oil lines again which if im honest bores the shit out of me after the fjt ones!
this HUC isnt too far off. had to have rear wheel spacers machined today to take up the slack in the back wheel,
chain is on now too. battery box and other wiring related crap on their way.
luckily i'm doing some work for a fabricator in his house so he's doing the chopper as a deal. no cash to change hands!
the tax man can shove that money up his arse!!  :rofl:

looking forward to seeing this one completed.
its booked in for paint at the end of december so rushing the fabricator to finish the frame,
full pearl/candy white on this one, i also bought a CRAFT RX1 Cobra helmet which will go in to get sprayed the same colour too!
what side stands do people use on these HUC's??? i'm really struggling to find something that'll work and can't be arsed to make my own.

with regards to the chain
the guy who sold me the chain said it would stretch a bit but shouldnt snap. surely it has to be BS rated or DOT or whatever its called?
i mean companys can't sell something thats that dangerous can they?
and a turbo fj wouldnt add anymore force to a chain that a normal fj could cause... surely the puny back wheel would break traction at the same time?
i will put a chain guard on it to save me a bit.

nice to hear feedback on the bike seeing as i've not seen anything like this before or built a turbo chop before!
Title: Re: fj1200 turbo "thug"
Post by: racerman_27410 on December 03, 2012, 09:06:41 PM
there are many different grades of drive chain.... all with different ratings on stretch/ wear and the amount of power they are capable of handling.

AFAIK the EK ZZZ chain is some of the strongest available.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on December 04, 2012, 12:50:41 PM
even the zzz chain isnt up to scratch!
Specifications

   Tensile Strength   9400 lbs
   Wear Life   1700
   Max CC's   1000
   Max HP   100
   Weight per 100 Links   3.97 lbs
taken from their website for their EXTREME sportsbike chain!

better off saving my money and putting it into a hefty chain guard i think!  :sarcastic:
Title: Re: fj1200 turbo "thug"
Post by: Havoc on December 04, 2012, 01:29:17 PM
Quote from: backstreetheros on December 04, 2012, 12:50:41 PM

better off saving my money and putting it into a hefty chain guard


When the 630 chain on my GS1000 went it smashed the crankcases to pieces wrapping itself round the drive sproket. I had one go on my 350LC and it locked up the back wheel sending me into a pond.  :empathy2:  . Least bad was when my Bonnie chain snapped on the start line at Avon Park Raceway spitting it backwards and wrapping it's self round the ankles of one of the watching MC guys, fortunately it had lost most of it's momentum and he wasn't annoyed, much   :good2:

They can let go in an infinit number of ways

(http://i214.photobucket.com/albums/cc122/cabletietom/SnappedchainmidFrance.jpg)
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on December 04, 2012, 01:50:08 PM
doesnt sound very nice! obviously this can happen to any chain at any time, just a case of luck and hoping you've got enough things in your way before it hits you i suppose!
shame the fj isnt shaft drive!  :rofl:
Title: Re: fj1200 turbo "thug"
Post by: Havoc on December 04, 2012, 02:20:39 PM
Quote from: backstreetheros on December 04, 2012, 01:50:08 PM

shame the fj isnt shaft drive!


Na dude, shafts sap too much power.

2 of the 3 instances above were poor maintainence and a worn chain.

The GS1000 on the back of a recovery trunk in the middle of France was actually a story in how strong chains are. Long story short. Bought bike 3 days before a tour of Europe with motor in pieces.
(http://i214.photobucket.com/albums/cc122/cabletietom/317_29670837570_9644_n.jpg)
Got bike together 30minutes before we had to set off. After 80 miles passing Cambridge it became apparent there was a massive tight spot in the chain. Tightened the chain on the tight spot and kept well oiled. We was in a hurry and the bald tyre was more of a priority, new tyre outside LeMans.
(http://i214.photobucket.com/albums/cc122/cabletietom/317_29670872570_1845_n.jpg)
Eventually spotted for a few days in Barcelona gave me time to source a chain.
(http://i214.photobucket.com/albums/cc122/cabletietom/317_29670842570_9985_n.jpg)
Counted links an bought good chain. Back at the site I realised I'd bought 530 section chain instead of a 630 :dash1:, doh. Did another 2000 miles just adjusting the chain on the tight spot every 100 miles across the south of France and back up through Italy and Switzland.
(http://i214.photobucket.com/albums/cc122/cabletietom/317_29670892570_2790_n.jpg)
(http://i214.photobucket.com/albums/cc122/cabletietom/317_29670887570_2481_n.jpg)
Eventually gave up the ghost about 200 miles short of Calais, that morning we'd decided Suzanne would be better off on the back of my mate as the chain was stoopid loose now, we were completely skint. Went with a bang pulling off a roundabout and apart from 4 liters of hot engine oil over the rear tyre, it was quite uneventful.

Sorry, mild hyjack, just got into the memories :drinks:
Title: Re: fj1200 turbo "thug"
Post by: ribbert on December 04, 2012, 04:21:18 PM


(http://i214.photobucket.com/albums/cc122/cabletietom/317_29670872570_1845_n.jpg)

I like the bush "jack"
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on December 04, 2012, 04:50:22 PM
haha bush jack is awesome.
seems like a good adventure!
i very much doubt if the turbo bike will go as many miles as you have, id be happy riding it once a month!
the gsxr bike i doubt will get much use either, thats much more likely to end up as an ornament in my living room!
we will see when i get them both finished!

boost pressure switch from wizards of nos arrived the other day and has been rolling about in my van.
still waiting on this bloody oil cap, which is still on the bench in my fabricators workshop! get on with it!!
i might disconnect his toilet in his house untill he completes the job for me haha.


a big thanks again to randy. (you know why) :good:
Title: Re: fj1200 turbo "thug"
Post by: racerman_27410 on December 04, 2012, 06:09:11 PM
Quote from: backstreetheros on December 04, 2012, 12:50:41 PM
even the zzz chain isnt up to scratch!
Specifications

   Tensile Strength   9400 lbs
   Wear Life   1700
   Max CC's   1000
   Max HP   100
   Weight per 100 Links   3.97 lbs
taken from their website for their EXTREME sportsbike chain!

better off saving my money and putting it into a hefty chain guard i think!  :sarcastic:


you are looking for trouble if using less than 530 chain..... which is the ZZZ chain i was referring to.


i dont know where you got those HP numbers as they are not on the EK site i'm looking at

http://www.ekchain.jp/product/extreme_sport.html (http://www.ekchain.jp/product/extreme_sport.html)

up to 1400CC recommendation.....11 thousand lb tensile strength..... every single one of the turbo busas at the maxton mile are running this chain.

start looking at specs on other 530 chains.... then come back and show me some better numbers.


i can tell you the 115 lb/ft of torque Brutus is putting on this chain has not stretched it.


But you can do what you want.... its your life (and leg/engine case)

kOokaloo!
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on December 06, 2012, 06:51:36 PM
got my oil cap back, turns out they didnt bother welding a pipe to it...
they only went and made up a brass hose tail then pressed it into my cap! not even a single tooling mark on the peice, very happy indeed...
so excited in fact i actually gave up work and drove all the way home (with a huge grin on my face) and fitted it to the turbo bike!
i was so caught up in the moment and fighting for daylight hours (04:05pm sun down!) that i forgot to take a picture.
i finished the turbo drain pipe with a nice bend to follow the line of the engine in (you guessed it) copper pipe.
got the oil feed to the turbo connected into the tapping in the block too.
i thought i'd run the bike for a bit to check for oil leaks.
ran for about 20 minutes and seemed to warm up fine, no horrible noises which is good,
i've not yet connected the fuel pump so it won't hold boost pressure yet... this is next on my list.
the bike will rev up and spools quite well, spits foot long flames with the dyna limiter set to 6500 rpm!!
left it running for about 20 minutes then the battery died as i've not yet connected the alternator.


the boost pressure switch i had to specially order from wizards of nos i fitted into the air pipe just before the plenum (next to the dump valve)
luckily back when i was doing the air pipes and found a 42,42,1/2" T in yorkshire brass i decided to use it, which ment i could thread a 1/2" T into this tapping, one side for the dump valve and one side for my pressure switch.

waiting on wiring loom, fuel pipe and electrical bits i've ordered now before i can press on. nice to hear it sit there and run for a while!!

been a bit tied up doing the gsxr chopper to try and get it ready for paint, got the exhausts done, the wheel spacers which seemed a shame to hide away as they were so well machined!! and a load of other crap. working through the problems we all face building bikes.

exhaust is a bit low, might need fettling...
(http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash4/320601_10151280633065827_1878688168_n.jpg)

(http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash4/380902_10151280638130827_375765246_n.jpg)




i also bought a CRAFT RX1 Cobra helmet to be sprayed white when the bike gets sprayed. nice job!

(http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/31558_10151281214685827_1115949844_n.jpg)

i'll try take some more pictures of the fjt when i get it out next.
Title: Re: fj1200 turbo "thug"
Post by: I make oil on December 07, 2012, 01:29:00 AM
Interesting thread and very well documented.   :good2:
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on December 17, 2012, 03:30:18 AM
As a fellow HUC owner (ive 3 of the things!),are you having the bike SVA'd,or are you doing what is commonly known as making a ringer? (Using the reg details of the donor bike). Im going legit with my stuff,as with new MOT rules coming along,the police not being as stupid as some people think etc etc,for me legal is the way forward. I can then sell them,knowing they dont have to have an mot test for 3 years,which a lot of people would think was a good move.
Its not a negative question,so dont take it the wrong way. Your bikes are as cool as a penquins cool bits,and I love them. But depending on how you go,it would be a shame to see you get yourself into any legal problems. :good2:
Im watching things with great interest.
(popcorn)
Title: Re: fj1200 turbo "thug"
Post by: JMR on December 17, 2012, 07:08:31 AM
 I think the JMC swingarm on the GS was the source of all your problems. :smile:
Title: Re: fj1200 turbo "thug"
Post by: Havoc on December 18, 2012, 06:42:17 AM
Quote from: JMR on December 17, 2012, 07:08:31 AM
I think the JMC swingarm on the GS was the source of all your problems. :smile:

Loved that arm, an early steel concentric. :nyam1:
Title: Re: fj1200 turbo "thug"
Post by: JMR on December 18, 2012, 07:04:14 AM
Quote from: Havoc on December 18, 2012, 06:42:17 AM
Quote from: JMR on December 17, 2012, 07:08:31 AM
I think the JMC swingarm on the GS was the source of all your problems. :smile:

Loved that arm, an early steel concentric. :nyam1:
I hope you got my sarcasm. I have a JMC on one of my bikes. After the 2 year wait to get it, paying for polish but getting it in the raw, modifications to get it to work etc etc I guess I'm happy.
JMC are gone but not forgotten (for the wrong reasons). My understanding is another company bought there jigs, blueprints etc and will be making them again with the emphasis on customer service.
Title: Re: fj1200 turbo "thug"
Post by: Havoc on December 18, 2012, 07:10:12 AM
Quote from: JMR on December 18, 2012, 07:04:14 AM
Quote from: Havoc on December 18, 2012, 06:42:17 AM
Quote from: JMR on December 17, 2012, 07:08:31 AM
I think the JMC swingarm on the GS was the source of all your problems. :smile:

Loved that arm, an early steel concentric. :nyam1:
I hope you got my sarcasm. I have a JMC on one of my bikes. After the 2 year wait to get it, paying for polish but getting it in the raw, modifications to get it to work etc etc I guess I'm happy.
JMC are gone but not forgotten (for the wrong reasons). My understanding is another company bought there jigs, blueprints etc and will be making them again with the emphasis on customer service.

Completely got it dude, I am well aware of the legendary F****p that was JMC customer relations. Oddly enough I only had positive experiences , a few years ago they did a drag slot extension by return of post, 'Lucky B*****d' was the typical response..  :unknown:
Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on December 18, 2012, 07:33:45 AM
Ive a couple of braced JMC swingarms too,but they wouldnt fit in with the chop builds here. :lol:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on December 18, 2012, 03:04:17 PM
sorry for my delayed response on this one...
been high demand at work as usual on the run up to christmas so havnt got anywhere with either bikes.
the GSXR750 will be a ringer as i already have the logbook for the donor bike and the engine numbers match.
the fj may have to go for an SVA but i don't know how that tallys in with not running any lights.
i don't want lights on either bike as wouldnt ride them at night anyway.
if the issue gets too bad with sva that will be a ringer too. i don't know how kindly the tester will take to my turbo or side exit?!
i think there will be a few interesting conversations with the law over the fjt anyway seeing as its so in your face and different.
just hope i can outrun them with straight line kookaloo speed!! haha.  :rofl:

the police around here are not too bad as i live out in the countryside. if your being an arse they will be an arse.

i've done absolutely nothing to the fjt in a while, i've bought a load of wire and connectors and ignitions and things so i can do the wiring loom properly when i get a minute to my self.
trying to find another sprinter van to join the fleet and another plumber employ but its proving to be quite difficult!!
i'll try get on and do some more work on the bike soon.
thanks for your interest and i really appreciate everyones comments and feedback on the bike.

my misses has started naming the bikes "rusty" and "not rusty" haha.

Title: Re: fj1200 turbo "thug"
Post by: dixiethedog on December 24, 2012, 10:38:48 AM
Did I see the gsxr HUC for sale on an auction site???? Ive been bored with mine for months,but once all the Christmas stuff is over,I shall be starting work on things again. I need to make some money for other projects. My AMA superbike/endurance styled FJ1200. :good2:

Merry Christmas.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 01, 2013, 08:41:12 PM
well spotted!.
its back on there again due to a time waster.
as much as i love the bike i need another van more than i need it
and its making me lose track of my fj!
i will get back on track with the fj and get all the wiring loom done when i clear some space getting rid of the gsxr
i still need to find for the fj...
anti-dive blocking plates, or anti-dive units to fit there (just so i can put oil in!)
a banjo bolt to connect my clutch hose to the master cylinder
a load of wire and alot of spare time...
does anyone have a wiring diagram for the alternator kicking around? i assume the two wires coming from it are live and sensor live? (both connected to battery?)
i'll get on with it soon!

on the upside... i did get a blacked out visor for my Craft RX1 Cobra and a set of carbon encrusted fox gloves from santa clause :good2:

updates soon...
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 15, 2013, 12:58:13 PM
right with the GSXR sold i no longer need to worry about it...
time to get back involved and finish this project.
i've managed to get the banjo bolt i was so desperatly searching for for the clutch slave cylinder.
i've taken the bike back out of storage to get on and complete the wiring loom.
got all the bits for it too.
starting my motorcycle licence on saturday as i am going to need it fairly soon.

i've let slip a little with this project but have recently realised how much i want to get it completed.
i'll get some more pictures to upload as all this text gets a bit boring after a while!..
Title: Re: fj1200 turbo "thug"
Post by: fj1289 on January 16, 2013, 11:46:03 PM
Good on you for keeping after it!  My ability to work on my projects comes and goes all the time  :dash2:  Think I'm on the 5th year with the dragbike...
Title: Re: fj1200 turbo "thug"
Post by: Kenny1098s on January 21, 2013, 01:22:01 PM
Hi Backstreet.

How bout a few new pics?
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 25, 2013, 04:36:15 PM
I have actually booked a day tomorrow to do my bik!!e
Thats how bad its got!
I will get some pictures tomorrow!
Title: Re: fj1200 turbo "thug"
Post by: Havoc on January 25, 2013, 05:08:12 PM
Excellent, me too, looking forward to the photos   :good2:
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 26, 2013, 12:34:47 PM
made a little bit of progress, although i got all my tools out only to have a call out at 8.30 AM for a broken boiler fan motor! inconsiderate!
on my way back i decided to stop in the local farm store and see if they had any clips i could use to hold my plenum on a bit better.
i found some silicone hose (not cheap) which was of suitable (if not a bit small) size to get the fit really tight.
(http://sphotos-h.ak.fbcdn.net/hphotos-ak-snc6/735237_10151373518200827_725917790_n.jpg)

i cut these in half to make 4 shorter peices, then as they were so tough i soaked them in boiling water for a while to soften them up a bit,

(http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash4/65195_10151373523480827_1091506134_n.jpg)
it took me about 10 minutes per hose to get them onto the plenum as so damn tight. after that i wrestled with the plenum to get it attached to the carbs.
took bloody ages to get it on there as such a tight fit but it is finally on! and airtight!
i replaced the shitty yellow hose i used to pressurize the float bowls with some black over-braid fuel pipe.
i also bought a load of new 3/8 inch fuel pipe to fit the pump.


the fuel pump is mounted there temporarily as its the only place i could bolt down that shitty bracket (im yet to find a decent way to mount a fuel pump)...
with the fuel pump installed i set to work doing the wiring.
(http://sphotos-h.ak.fbcdn.net/hphotos-ak-snc7/483026_10151373514630827_48964339_n.jpg)
the ammo box i used is quite large but is a surprisingly tight fit to get all the electrics and components in there!
i wired the starter solenoid so it is in the bottom of this box,
the dyna 2000 ignition module is in this box too.
i wired the retard trigger wire to the normally open switch i had made from wizards of NOS which i previously fitted in the boost pipe to the plenum.
i fitted an ignition key in the front of the box as its a bit safer than just a switch ignition. there is also plenty of space here for an ignition light and some switches.

(http://sphotos-c.ak.fbcdn.net/hphotos-ak-prn1/64237_10151373507805827_70533271_n.jpg)

the bike now seems to act a bit more sensibly in the top half of the revs, ive set the retard trigger quite low and set the igniton to 12 degrees retard and it seems to spool up nice,  yet to turn the rev limiter up off 9000 yet though...
spits a nice foot long flame when you drop the throttle.

it idles like a bag of shit but i guess thats because its now jetted completely wrong for the plenum and turbo and that.

few teething problems at the moment...
1 the overflow tapping in the bottom of the tank i now am using for a return from my malpassi petrol king fuel pressure regulator spews petrol towards the top of the tank and leaks out from around the filler cap fitting.

2 my nice shiney new clutch slave cylinder is no longer nice and shiney as it spewed oil out from the casing when the engine reached oil pressure... i guess this is just an O ring??

3 i need to find out where the idle adjust screw is on these carbs as it wont idle (or does very badly)

4 my gear linkage from the forward controls is shit, its too flimsy and needs replacing.

i'll get more pictures tomorrow as i ran out of light today due to some very cold customers.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 26, 2013, 12:57:56 PM
here's where the petrol is escaping from the tank, obviously i'm not going to paint over it.
(http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/550287_10151373554485827_2122452439_n.jpg)

heres the boost pressure switch that controls the ignition retard under boost.
(http://sphotos-e.ak.fbcdn.net/hphotos-ak-snc7/385302_10151373569380827_249098062_n.jpg)

sorry about the shit pictures its dark... i'll try get some more tomorrow.
Title: Re: fj1200 turbo "thug"
Post by: racerrad8 on January 26, 2013, 01:18:48 PM
Quote from: backstreetheros on January 26, 2013, 12:34:47 PM
2 my nice shiney new clutch slave cylinder is no longer nice and shiney as it spewed oil out from the casing when the engine reached oil pressure... i guess this is just an O ring??

Not sure where the oil came form, but there is a seal on the clutch pushrod to seal the oil.

Clutch Push Rod Seal (http://www.rpmracingca.com/proddetail.asp?prod=Engine%3AP%2FR-SlaveSeal)

I wonder if it popped out when the push rod shot out before you installed the slave cylinder.

Randy - RPM
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 26, 2013, 01:54:44 PM
quite possibly, i didn't see that though...
I've just ran the bike again and its coming out from the top bolt on the clutch slave...
i'm hoping the seal has gone and someone hasn't put a bolt too long in there and punched a hole behind the threads?
i guess i could use some thread sealant to put the bolt back in?

randy can you point out the idle adjust on these carbs for me?
surely i can just tighten the throttle cable a bit. i will be looking to have the bike re-jetted and dyno'd properly after I've got it to a ride-able stage.
i'm leaving the clutch pipe and chain till last to stop myself taking it up the road for a cheeky hack. its oh-so-tempting!  :rofl2:

Title: Re: fj1200 turbo "thug"
Post by: racerrad8 on January 26, 2013, 04:04:23 PM
Quote from: backstreetheros on January 26, 2013, 01:54:44 PM
quite possibly, i didn't see that though...
I've just ran the bike again and its coming out from the top bolt on the clutch slave...
i'm hoping the seal has gone and someone hasn't put a bolt too long in there and punched a hole behind the threads?
i guess i could use some thread sealant to put the bolt back in?

randy can you point out the idle adjust on these carbs for me?
surely i can just tighten the throttle cable a bit. i will be looking to have the bike re-jetted and dyno'd properly after I've got it to a ride-able stage.
i'm leaving the clutch pipe and chain till last to stop myself taking it up the road for a cheeky hack. its oh-so-tempting!  :rofl2:

Okay, I just drilled a case where the upper bolt goes and there is no way I can see a bolt could leak oil.

Are you sure it is oil and not brake fluid leaking from the banjo bolt?

The idle speed screw is underneath the carbs between the two center carbs. It has a thumb screw that for turn to control the idle speed. if the carbs have been sitting I would say the pilot jets are plugged and the reason for the poor idle.

Randy - RPM
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 27, 2013, 01:18:56 AM
100% its not brake fluid as i dont have the clutch hose connected yet  :morning2:

it may just be that the oil coming from the clutch push rod choses the easiest path out of the top of the clutch slave cylinder.
its not just a drip, it really flows out. so much so that i had to stop the bike.
im thinking maybe the seal around the pushrod (but saying that i ran the bike for 3/4 hour with the plenum disconnected when checking the oil cooler and turbo oil feeds for leaks?)

maybe because now i can hold a steady high rev with my fuel pump connected
where as before i could only blip the throttle as boost pressure would push the fuel back out of the carbs and it would die?...

i'll pull it apart today and see whats going on... up at 07:00 am on a sunday... thats how dedicated i am to doing some more work on this bike!
:crazy:

Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 27, 2013, 12:23:35 PM
heres a better picture of the plenum attached to the carbs
with the idle adjusted (thanks randy) the bike will now idle.
(http://sphotos-a.ak.fbcdn.net/hphotos-ak-snc6/734758_10151375541535827_153122600_n.jpg)

pulled the clutch slave cylinder again today due to the massive oil leak...
it looks as though the oil was coming from the top bolt of the clutch slave cylinder....
(http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/69692_10151375544370827_1462092447_n.jpg)

i was disappointed to see the clutch push rod rubber intact.  :dash2:

the oil is clearly coming from the top bolt hole
to me it looks like in the past the chain has come off and pulled off the slave cylinder in the process hence why it was missing.
there is also a gouge out of the engine casing by the push rod

if you look closely you can see the cracks at the bottom of the upper bolt hole

to test my theory that the upper bolt was leaking oil i decided to try and start the bike... then i stupidly realised i had entered the "spear the cat" game... :mad:

(http://sphotos-g.ak.fbcdn.net/hphotos-ak-snc7/428213_10151375549690827_806183592_n.jpg)

i don't readily have the availability to weld engine casings so some chemical metal found its way into the hole...

(http://sphotos-a.ak.fbcdn.net/hphotos-ak-prn1/73757_10151375553725827_642819858_n.jpg)

the bike now idles properly, i left it for a while to idle and it seems to not be too far off
i decided to get brave and turn up the rev limiter!

on revving the bike it gets to about 6000rpm under its own steam pretty quickly, spits a good flame when you let off the throttle too,
if you hold the revs at about 6000 it starts to feel almost a bit flat, like there is a barrier while its building boost...
then after probably half a second of being flat the bike hits 9 psi of boost pressure then it literally slams into the rev limiter almost instantly, you can't really hear the revs climb, its just like a huge bark and on the rev limiter the bike spits a steady foot long flame from the exhaust...

if you stay on the limiter for a second then dump the throttle, you get a mix of dump valve and wastegate chatter as the revs drop, but they seem to stay really high after a good limiter bash... doesn't fall back to idle... is it possible that the main jets are too big so its over fuelling and staying high?
a tiny blip on the throttle brings the revs back down to a steady tick over.
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 28, 2013, 09:42:20 AM
done a little bit more today, i went and bought a large rubber diaphram for some milking parlour machine,
cut it up and made a nice rubber gasket to seal the petrol cap plate to the tank...
this was all well and good but after doing this i started the bike, ran ok for a little while then the revs started to climb on their own!.
i quickly turned the bike off before it had chance to start spooling uncontrollably.
turns out the fuel pump is pressurising the petrol tank that much its forcing it past the floats in the carbs and filling up the cylinders!
i took a trip to my local bike mechanic/tuner
explained to him what happened and the hesitation in the fuelling.
he told me that the fuel pressure is way too high, its overfuelling loads before it gets chance to spool up and get more air into it... this explains the foot long flame from the exhaust!
he reccomended i practically open the wastegate to reduce boost pressure as much as possible then slowly edge it all up till it doesnt work right lol :sarcastic:

if you've got an adjustable boost pressure switch controlling your ignition retard... make sure the screw isnt backed out so far the contacts inside touch... trying to start the bike with 12 degrees retard makes some extremely loud backfires! (nearly blew the windows out! :wacko3:)

i'm going to try adjusting down the fuel pressure regulator to as low as i can get it before i get carried away and buy new things...
the problem with the tank has annoyed me so much i've just bought parts to make a new 2 part tank.


(http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/542546_10151377381120827_1332993088_n.jpg)

i thought if i cut 2" off the cap side of one of these tanks... a solid baffle could be welded in to retain the petrol, then the 2" part could be used as a water resivoir for the water cooling side of the turbo.
i'm very tempted to just ditch the copper radiator and have a loop of pipe running right round the outside of the bike to cool the water...
i don't think there is any harm in heating the petrol a little from the tanks transferred heat is there?
two of these tanks would be mounted side by side, then one cap would be for the water and one for the petrol although it would look like they are both petrol caps.

then i could weld the necessary vents, feeds and return lines into the tanks without messing around with the crap tank i have at the moment.

much easier.

i'm now trawling the internet looking for how to adjust the fuel pressure on my fuel pressure regulator  :dash2:

Title: Re: fj1200 turbo "thug"
Post by: Seanextra on January 28, 2013, 12:27:55 PM
Hi Loving this build,

                      I would say No to Hot Fuel !!! 2 Reasons first being safety, as hot fuel will pressurize the vessel and if its vented it will be spewing out fumes just waiting for a light !  2nd reason would be that HOT fuel is not what you want for making power and sort of makes going turbo seem like alot of effort for less gain, Many old school drag cars use to run a temprite which was a small alloy can with an alloy coil running thru it which was between the fuel tank and Carbs this would be filled with ICE before each run and would pre cool the fuel which created a similar but primitive effect of NOS injection, and also similar to what an intercooler does on a Turbo. By pre heating your fuel you are doing the oposite of this and im sure would create problems with atomization of the fuel in the carbs. This is also why the stock FJ engine ran a heat shield in front of the carbs to stop heated air from the cylinders and head preheating the fuel in the carbies.

I may be wrong but this is what i know to be the situation when it comes to Fuel temp etc... maybe someone else here might know a bit more on the subject.

On another point i see you are pressurizing your carbs from the plennum outer edges do these pipes lead to a venturi into the path of the incoming air or are the just plumbed to the edge of the plennum?

What fuel reg and pump are you running looks like a holley blue pump?    Is your Regulator Boost regulated or just static?    What Turbo is it and the Specs? What Size Jets are you running, Needle position and turns out on pilots ? :drinks:


Regards Sean   

Keep the posts going  really interesting to see your findings.


Title: Re: fj1200 turbo "thug"
Post by: andyb on January 28, 2013, 01:39:14 PM
A little heat won't be a killer for the fuel, but using it as a coolant or a heatsink isn't a good idea.  I mean, the stock air cooled engine has 5 gallons of petrol directly above it, and it gets decidedly warm at times.  Not a huge problem normally, but you still shield it from heat when you can.

As for the way fuel reacts when heated, there's a couple points.  Hotter gas will lose the lighter components, changing your tune as it gets artificially aged from the heat, and that's going to be the problem, rather than expansion changing density.

Sounds like you need to run a lot, lot less fuel pressure, like 3psi or so during offboost or vacuum times, and then use a rising rate regulator to give added pressure during times of boost.  At idle you'd want say, 3psi of fuel as a baseline, but at 20psi inlet pressure you'd have to have 23psi to maintain the same delivery rate.  Jetting past that is another problem, as it's going to do some strange things at partial boost and so on.  Really the only proper way to even see what it's doing will require a datalogger, possibly a Wego unit.

If you use a normal pressure regulator on the fuel system, as the boost pressure builds, it'll go very lean and proceed to shove air backwards through the fuel pump.  Not a good thing.
Title: Re: fj1200 turbo "thug"
Post by: Havoc on January 28, 2013, 03:38:21 PM
Don't the pitot tubes from the up pipe balance the pressure to the carbs. CV carbs don't need rising rate like an EFI do they?
Title: Re: fj1200 turbo "thug"
Post by: Seanextra on January 29, 2013, 12:53:59 AM
On a Turbo you still needs to balance the incoming Fuel Pressure to Compensate for the incoming charge pressure otherwise as andyb states it will try to blow air back up your fuel line which would lead to a Very Lean run and in short time one Rooted Engine.  $$$


Rising Rate or boost controlled Regulators are plentiful and not expensive i cant see how you could get it to work effectively without one on any carb set up ?


Regards Sean
Title: Re: fj1200 turbo "thug"
Post by: Havoc on January 29, 2013, 01:22:48 AM
My understanding was the pitot tubes 'fool' the CV carbs into behaving like they are opperating at 100,000kPa. They would behave differently from flat slides? and I completely get that EFI require rising rate. Boost would force CV carbs closed by cancelling out the negative pressure provide by the suction of the motor. As long as the float bowls stay full of fuel under constant pressure there wouldn't be a problem with leaning out. It is very early and I'm very tired though  :flag_of_truce:
Title: Re: fj1200 turbo "thug"
Post by: andyb on January 29, 2013, 02:30:12 AM
CV carbs don't really respond to vacuum, they respond to air pressure differential.  You have to give a reference signal to one portion of the carb so that it sees the pressure changes as a function of airspeed through the venturi rather than as a function of boost pressure.

There's no chance you can use a fuel pump to push 3psi into a 10psi bag.  Just doesn't work, and that's why you have to have a rising rate regulator.  Sure, you can run the fuel at a higher pressure all the time, but then it's going to leak like hell past the needle seat anytime you're not on boost.

The problem is at this point you can very quickly do much damage to the motor.  Get things as figured out as you can and take it to a dyno with a good tuner.  Yes, it'll be expensive, but it'll be vastly cheaper than a set of pistons, say.
Title: Re: fj1200 turbo "thug"
Post by: bcguide on January 29, 2013, 03:16:42 AM
How about seting your fuel pump for normal atmospher and then run a line from your plentum to the fuel tank. If your tank is pressured up from the turbo
your fuel should still flow to the carbs
Scott
Title: Re: fj1200 turbo "thug"
Post by: andyb on January 29, 2013, 04:41:59 AM
The tank still needs vented for normal use.  It's not the first time a turbo has been done through carbs, go with what's worked for others, yes?
Title: Re: fj1200 turbo "thug"
Post by: Havoc on January 29, 2013, 06:07:52 AM
Got it. Just having a brain freeze. Ta
Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 29, 2013, 05:42:46 PM
try and answer a few questions here...
the hot fuel was only an idea, i think i'll just go for a separate resivoir.
does the plenum sides lead to a venturi? i don't know what your talking about.  :wacko3:

the plenum is linked directly to the carbs and the plenum outlets are bigger than the carb inlets to make sure all the carb holes arnt blocked if slightly out of line.
the 4 tubes you see coming off the plenum are pitot tubes. two pressurize the carb diaphragms with (plenum) boost pressure) and the other two, one goes to pressurizing the carb float bowls to equilise the pressure inside, above and below the carb intake. the other goes to the fuel pressure regulator to cross reference the fuel pressure with the boost pressure so the fuel pressure is always higher than the pressure in the carbs (air pressure)

the regulator i used is a Malpassi Petrol King boost referenced model with a single carb outlet (although i have four carbs i have one fuel inlet pipe)
the pump i bought on ebay off a guy who said he took it off his GSXR turbo drag bike. its a brass gear driven pump, i believe made by seaflo.

the turbocharger used is a Subaru Impreza TD04 with a built in adjustable wastegate. standard mounting flanges (in case the turbo blows up) but completely custom manifolds.

the dump valve i believe is a bailey model
the boost pressure switch controlling the ignition retard under boost is a Wizards of Nos normally open switch.
the jets are standard as are the carbs.
needle position is standard as is the pilots. the only thing i've adjusted is the idle screws.
the bike is being sent to my local mechanic for re-jetting and fine tuning of boost and fuel pressure and ignition map. hopefully we can get a dyno figure then.

i think to get it running a bit better i need to adjust the fuel pressure regulator down (i've bought a fuel pressure gauge for this very reason)

still a fair amount of work before its ready to be sent away for jets and dyno.

i had alot of problems with my fuel tank over pressurizing due to it not being vented. a potential bomb! :bomb: hence why i'm going to make a new tank (or set of tanks)
then i can ensure it has the correct vents, return lines and feeds.
need to find a liquid filled boost pressure gauge as the one i have nearly shakes itself off its mounting on idle. i could connect this to the plenum and maybe it wouldn't be so erratic.

my MOT tester said don't bother putting a speedo on it because you can just use your satnav.
i have the ignition all wired up on a key now and the alternator wired so i dont have to deal with a flat battery and touching wires together all the time! haha.


Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on January 29, 2013, 05:56:08 PM
just re-read. the pitot tubes are not into the venturi, they are just piped to the outside of the plenum, not ideal i know but i imagined it would be way too difficult to get the pitot tube sizes perfect for the air pressure to be accurate.
(http://sphotos-f.ak.fbcdn.net/hphotos-ak-prn1/734048_10151380017705827_410136796_n.jpg)
remember this isnt a drag bike, its a hardtail. so i don't think its worth the trial and error on putting them into the path of flowing air to get it perfect.
i'm not after 100% performance with this bike as the style of the bike isnt exactly suited to full on drag power.
i'll be happy if i get an extra 50hp over standard and it runs right (and makes alot of noise :crazy:)
Title: Re: fj1200 turbo "thug"
Post by: Seanextra on January 30, 2013, 05:49:35 PM
All good thanks for sharing, Just interesting to see what you have done. This is all new ground for me also, its great to see a living breathing project with pictures as it evolves. I am still getting all my bits and pieces together and holding off on a few big dollar items till i get closer to needing them. I have read alot of Turbo builds with Carbs ( Blow Thru ) and nearly all of them have ended up with either stock or close to it Jets and Settings. a bit of progressive retarding to keep that deadly pinging away and mucked about mainly with pressure to the carbs etc to get the fueling right or as close as possible thru the full rev range. I think that is the area that needs the most effort. 

Have you thought about a priority breather valve for off boost intake>?? seen some good ones made out of 2 Stroke Dirt bike reeds on to the plenum simple and fool proof fix and you can get a good used set pretty cheap. I'm sure it would help down low with your road application.


Regards Sean

Title: Re: fj1200 turbo "thug"
Post by: backstreetheros on February 28, 2013, 05:59:13 PM
bloody bikes!.
i've not had chance to do anything as been on the catch up with work,
moved into a new lockup this weekend so have a bit more space and hopefully peace and quiet to work on the bike!
its not been forgotten! :good2:

i've had a think about a priority breather valves and although a good idea i think its way over complicating things...
and if im wrong and i can't get it set up right on the road, i'll make one and fit it!  :sarcastic:
i'll look further into getting it to run right after i've made it ride-able!
i no longer have a little sump drain plug guard on the bottom of the motor now as the bike ground out going into the new workshop  :rofl: