GS(X)1100E turbo EFI

[ArttuH]

Next step will be building the exhaust. All the parts are already collected.


DIY stainless silencer kit for 2.5" pipe, water cut downpipe flange and pile of stainless pipes, straight and bent. Should be enough for one exhaust...

[madjack57754]

You wouldn't get any lift from the rocker change . What you get is better geometry when running high lift cams. Less side loading at higher lift. Not a real problem with a turbo set up.

[ArttuH]

The exhaust is getting shape.




The can will be cut shorter when I install inner parts in it. The passenger pegs are real PITA when building the exhaust. It's just impossible to place the can so that it looks good and gives enough ground clearance.

Water injection components will need more space so I built new fender that gives more space under the seat.

[ArttuH]

Then it's time for the intake side.

Finished throttle bodies.



And some relating stuff. 630cc secondary injectors that will be placed on the plenum, fancy adjustable billet fuel regulator and some bits for the plenum.

[ArttuH]

Let's see for a change an example of failed building attempts. Plenum front wall and inlet stubs. Take 1.

Place the stubs on the throttle bodies and tack them on the plenum front wall. Check that they are still in correct position. Looks good.



Clamp the assembly on the table to prevent distortion and weld the stubs properly. (I'm still learning alu welding.) Ok, it stayed pretty straight but the flange gained a couple of millimeters length. So no hope to fit it on the TBs anymore



Then some desperate fixing attempts and melt one of the stubs to unusable condition. Game over!

[ArttuH]

Plenum front wall and inlet stubs. Take 2.

So I decided to take new angle of attack on this. I realized that I have the GSXR air box rubber boots that actually look quite handy. So let's see what I can do with them.




Looks pretty good except length difference. So I have to get another set of these rubber boots to get equal length set. Only question is if the boots will stay on their place under the boost but I'm quite confident. They fit in the holes quite firmly.

[ArttuH]

The plenum is finally ready. It's a good thing that I don't have to make these for my living, it wouldn't be too good business...

Internal parts:


And finished item:



Now I just have to decide if I will polish it or just paint it black. Right now I'm leaning towards painting. After spending several hours by scrubbing exhaust pipes trying to make them look decent I got a strong feeling that polishing is pretty pointless work

Anyway, the exhaust is also ready except the end can bracket.

[49er]

Good stuff

Well done Arttu. That plenum chamber looks well designed. It should provide even boost over each cylinder. If they're a good tight fit, those rubber velocity stacks should seal ok with the boost levels you'll be using.

Ali's a very challenging metal to weld. It's real easy to input too much heat on thinner sections. Painting it black will probably assist with heat dissipation too.

Hope it runs as good as it looks.

[ArttuH]

Ali's a very challenging metal to weld. It's real easy to input too much heat on thinner sections. Painting it black will probably assist with heat dissipation too.

Yep, that's true. I should learn to use foot pedal with my TIG, it would be handy in many cases. But first I have to modify the pedal slightly. Currently it's adjusting current from zero to 300A so it's virtually useless. I'm going to add pots to adjust min and max currents, then it should be fine.

Not sure about heat dissipation with black paint. Keeping in mind that there is a hot engine next to the plenum it will probably absorb more heat than dissipate.

Hope it runs as good as it looks.

Let's hope so

[gmansyz]

TB's

Hello Arttu
What did you do/use to plug the secondary shaft holes in the TB's? Epoxy or weld? Or?
Tanx
G

[ArttuH]

Hi Greg,
I tapped the shaft holes for 10mm thread and used screws with glue to plug them. Then I just ground screw ends flat from inside of the throttles.

[ArttuH]

Plenty of tinkering but so little visible progress...

I needed more space inside the rear cowling for water injection tank so I converted the tail light into LED version.



The result is much slimmer and in addition I got brighter brake light with less than half current draw.
Original one on the left and LED version on the right.



Then there was enough space for water tank. 1.5 liters, I guess it's enough for almost anything.



And mock up on the bike. The water pump found it's place as well.



I guess that larger oil cooler wouldn't be a bad idea. So I mounted a 13 row Mocal cooler, should be enough, I think. Initially I planned to route oil through water passages of the turbo but plumbing for that was looking desperate so I gave up the idea.

[ArttuH]

Finally some progress on the engine side too. I got the crank back after various set backs and long waiting. But good things are worth of waiting. The builder claimed that this was one of best cranks that he has ever done. Run out is less than 0.01 mm, it was impossible to see any movement on the dial gauge while spinning the crank! The clutch obviously got straight cut gear and HD backing plate.




I also decided to open up the crankcase mouths while the engine is in pieces. Just in case if I go crazy some day and want some big block

[49er]

Good move machining the case sleeve clearances. Means you don't have to split the cases again to go BB.

I bet that run out figure is better than most achieve after welding those cranks, even the Suzuki factory jobs!!

[ArttuH]

I bet that run out figure is better than most achieve after welding those cranks, even the Suzuki factory jobs!!

Yep, factory spec is less than 0.1mm and I have heard that many factory cranks actually doesn't meet this spec.