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  #331  
Old 10-04-2011, 11:57 AM
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Sat outside in sunshine all yesterday afternoon scrubbing away removing oily hand prints, metal swarf and general smeg. Loads of sheep shit from going up n down road outside my house too. Lol. Good proper clean and polish n all sitting ready for the photographer. :-





Updated n fitted new spec sheet on back of flip down numberplate thing. :-



Basically just cleaned crap out of it to make it as good as can be for pictures. Get photo session out of the way then start proper setting things up boost wise n lots of road testing, etc. Muwahahahaha…………

Side-on shot showing the lowered back end. Only couple of inches but made all the difference to the handling n reckon its sitting better now tbh too.:-

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  #332  
Old 10-04-2011, 12:02 PM
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We could pre approve the female ...bikes lookin fine but cmon harris would ye want to waste a damn fine bike by having some ugly lass hangin all over it
I know her. Registered with pro-model company n been in few tv programmes. Waiting on SF mag agreeing to pay her n sorting it out. Worst case it'll be me in a mankini in photos.
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  #333  
Old 10-04-2011, 07:35 PM
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Worst case it'll be me in a mankini in photos.
Owwwwww nooooo ye could cause blindness mental scarring or worse........
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  #334  
Old 11-04-2011, 08:40 AM
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Owwwwww nooooo ye could cause blindness mental scarring or worse........
I know, I don't think there's enough mind bleach in the world for that ...

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  #335  
Old 11-04-2011, 01:04 PM
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And lo, in one fell swoop the focus of the thread shifted from the bike to things that should never be seen........
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  #336  
Old 11-04-2011, 05:09 PM
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I just came back and found I've not logged off...I can't remember the last time I posted/logged on...!!!

I wonder if that is some kind of record??
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  #337  
Old 28-05-2011, 06:18 PM
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Not touched bike for about a month now tbh. Had my head down between busy airbrushing workload and working on my daily driver hearse every evening and weekend giving it a good sorting out mechanically.

Didn’t want to touch the bike till Streetfighters magazine photographer had been. His dates for coming up turned out to be completely different to what we’d initially thought though. He’s not due up this way till July or even August. Im not sitting on my arse for that long waiting, so sod it time to get the bike covered in oily handprints again. Lol

Want to get it boosting right, etc. Had a cylinder 3 filling up with fuel on and off lately and after tapping the float bowl I decided I had to whip carbs off and see what was what. Also getting boost leaking out round the plenum when boost starts to build.

Took the lot apart this afternoon in between clear coating helmets. Lol.:-



Stripped carbs and turned out to be a tiny bit of dirt in cylinder 3’s carb just stopping fuel cut-off valve from seating right. Cleaned out all 4 carbs anyway to be sure. Ordered up a cheap inline filter off Egay for the fuel line to stop any more crap coming through into carbs. I’ll mount it before the fuel pump when gets here.

The plenum I’ve never been 100% happy with. I did my best with junk metal and a stick welder, but it was never right. The plenum ports and carb mouths didn’t align quite right and overall it was a bit shit. Took it off and threw it in junk pile! Chopped back silicone hoses and clamped them up tight on carbs ready for new plenum. :-



The only bit of the old plenum I kept was the air hose fitting off the top. Lol.:-



Measured up the carb port spacing accurately with micrometer this time rather than a ruler with half the lines worn off. Probably a bit more accurate. 10 mins on google sketchup and got a good idea and dimensions needed. :-



I was going to order up some more steel and cut out the parts and jig it all up accurately and then pay someone with better welding gear locally to weld it properly for me. My mate Emoe (Hayden cycles) though is needing some paintwork doing and just so happens to be a bit handy at engineering. Lol. He’s going to make up a nice posh Tig welded alloy plenum for me which will be super accurate and line up with carbs 100% right. No more boost leaking for me hopefully. Miles better than what I can make with equipment I have so pretty excited about it tbh.

Also ordered up this £9 delivered inline fuel pressure gauge as the scrap one I plumbed in originally turned out to be a dud. :-



Should allow me to set up the fuelling nice n accurately statically, and see whats happening when builds boost with new plenum on.
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  #338  
Old 30-07-2011, 04:58 PM
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New plenum in the mail somewhere on way to me. Exciting stuff!

Emoe (Haydencycles) made it for me in exchange for sorting out his tank paintwork for him. We opted to make it out of steel to ensure accuracy during welding and he had some suitable material for main body sitting in workshop. Also went with a rectangular section as he had some suitable box section in stock as I say, and looking at dimensions it gave me more clearance on the bike around the plenum, and a greater internal volume too which should ensure pitot tube pressurization of carbs works correctly. Also easier to machine/clamp up for welding more accurately than round body, so just better for both of us really.

Have to say although Emoe’s a friend I really rate his work. Top stuff. He sent me some pics of the process. Thought I’d post them up for folk that are interested in the mechanical porn side of things. I’m no engineer, but love these sort of pics of folk doing what they do with theyre skills. Puts my engineering skill set to shame.

The 4 inlet stubs and up-pipe connection from turbo feature turned ends on the lathe to ensure positive location to main body during welding. Neat.:-



Main body holes chopped out with super accurate port spacing on CNC mill.:-



Heres a close up of the little lip on the ends so everything lined up 100% before any welding even.:-



Quick tap n everything in place for welding with no chance of moving about.:-




Out with the Tig.:-

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  #339  
Old 30-07-2011, 05:01 PM
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Continued..........


Kinda puts my stick welding to shame. Lol.:-



Ends getting tacked on.:-



Getting there, just pressure takeoff point n up-pipe connection to go.:-



Threaded insert being welded on for my hose fitting to feed carbs/pressure regulator, etc.:-



Up-pipe on n all finished. Looin forwards to getting it in mail.:-




Give it a lick of paint when here and get it bolted on, n take it from there really with the bike. Should be free of pressure leaks n building boost n ready to run n setup. Insurance set up for the bike so hopefully not far off the road now got this vital piece sorted out professionally.
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  #340  
Old 30-07-2011, 07:08 PM
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He's done a grand j*b with that.
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  #341  
Old 02-08-2011, 05:09 PM
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Mail came this afternoon.:-



Ran out after airbrushing and mixture of good n bad really. Good thing is ports are bang on and lines up perfectly to the mm.:-



From the side it fits comfortably in space too.:-



Then went to slip it into silicone joiners to carbs n wouldn’t sodding fit. Im stronger than average person but even straining away like a constipated guy on a toilet I couldn’t get more than 2 ports in more than 5mm. The problem is the carbs are 58mm so when clamped up tight I’ve not got enough joiner length to slip in the plenum ends. Basically the silicone joiners are too short and need to be the length of this scrap bit in picture. Bout double the length of old plenum joins. Balls! :-



Hey ho not end of the world. Going to order up some more silicone tubing. Gives me a few days to primer/paint up the plenum a nice blue, cut down couple of sections of up-pipe to suit new plenum location and get few other odds n ends sorted. Not held me back as such. Few days n should be able to hit the starter again.

Fook me though. Having not worked on the bike for few weeks I lifted the cover today and just stood there thinking `Jesus that things mad as fook`. Lol. Funny how perceptions change when not seeing it every day.
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  #342  
Old 02-08-2011, 11:47 PM
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spam on ..is toast..lol
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  #343  
Old 03-08-2011, 01:13 AM
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spam on ..is toast..lol
what??

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  #344  
Old 05-08-2011, 05:58 PM
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Held of spraying plenum last couple of days. Didn’t want to spray it then find up-pipe tube needed cut or brackets welded on, etc. I was also contemplating welding on brackets to add some tie-bars to head to hold plenum onto carbs under boost.

New silicone tube came in today’s mail. Had just finished the artwork karting helmet so had couple hours free to head for the man-cave (garage).

Chopped the 250mm into 4 equal lengths. Didn’t want to cut it too short first try. Bolted them to carbs, slipped on new plenum.:-



Test fit of side panels though wasn’t good. Too much of a gap to frame.:-



Kept trimming off small 5mm widths till it sat better.:-



Perfect port alignment and fits in there nicely.:-



Slipped 90 degree bend onto bottom of plenum and fits in space and lines up fine ready to reconnect plumbing.:-



Test fit of side panels and seat better this time. Slight gap but less than was there before with old plenum and nothing worth worrying about.:-



As for adding tie-bars, etc I’ve decided not to tbh. Plenum is feckin solid onto carbs and that’s without the clamps on! Cant physically pull the plenum off by hand, the rubber sticks that well to the longish plenum stubs. Nice snug tight fit. When connect up up-pipe connection, etc the plenums held pretty damn solid on there. Only running low boost so I’m confident it wont go anywhere.

About to primer and spray the plenum blue tonight. Only clear coating customer airbrushing tomorrow so should be able to get plenum back on and reconnect all the hoses/fuel lines, stick bodywork back on, etc this weekend, as taking Sunday off (worked last 4 or 5). Aiming to get the base fuel pressure setup to 3-4 psi once back in one piece, hit the starter and see if from there. Hopefully be building boost this weekend. If not then I’m a damn sight closer to it.
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  #345  
Old 07-08-2011, 10:00 PM
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Worked every weekend for last month or two, but had this weekend mostly off work so it was MANCAVE time!

In between clear coating a customer lid yesterday I got bike back together after painting plenum metallic blue on friday night.

Everything plumbed in and side panels on, etc.:-



Switched on ignition, fuel system refilled after 10 seconds or so, then set base fuel pressure to 3.5psi over boost level.:-



Hit the starter and…………………………..nothing much. Starter groaned over very slowly. Sodding battery flat. Lol. Hooked the charger up and sat clock watching out the corner of my eye for few hours waiting to push that button.

Battery charged and I fired it up Saturday night. Sodding smoke everywhere (and I mean everywhere) and crawled my way to garage door to find huge mushroom cloud above garage. Lol. Went back in and carb number 3 again was pissin out fuel at the bottom of the float bowl and also flooding the cylinder which raised the oil level in the crankcase with excess petrol cutting off the drainage for the turbo, hence pissing it out the exhaust.

Went into the house last night a bit pissed off tbh, but after thinking the problem out and speaking to few mates and folk on OSS I knew where problem was.

Fuel float heights in carbs needs to be adjusted for turbo use to compensate for higher baseline fuel pressure in carbs with turbo use. Took bike apart this morning and cleaned out the carbs :-




Quite a bit of crap in there considering I cleaned em out few weeks back but that was before inline fuel filter was added. I also changed the placement of the inline filter to after the fuel pump and before the regulator like advised by a helpful guy on OSS.

Got carb heights set at 16.5, about 2mm larger than 14.6 measurement of stock which means 2mm lower fuel height in carbs when flip carbs right way up.:-



Bike back together and no fuel leaks out bottom of carbs, no fuel going into oil again as far as I can tell as oil level didnt change after running it. Started off the button each time, rev's fine, etc. Tickover fine, etc, etc. Also lowered base fuel pressure to 2psi.

Still getting some smoke out of turbo slightly but oils contaminated so much thinner. Plus when look through sight glass on clutch cover the petrol contamination is foaming up, etc n prob blocking draining slightly. Wee bit of petrol coming out of oil breather too but again understandable as petrol foaming n condensing in breather tank. Change of oil should cure both probs. Going to try get oil tomorrow at next village and flush/refill. If not its an order online job yet again. One of the hassles of living in middle of nowhere.

Wasn’t building boost though and I was really discouraged tbh as felt like I was close after a whole weekend at it.

A very knowledgable guy on OSS did inform me however that it would’nt actually show boost unless under load (i.e. on the road). Was speaking to Emoe (Haydencycles) online and he was telling me his old 680bhp Subaru impreza running 50 psi would only build 1 or 2 psi of boost in neutral gear max.

Emoe gave me a prod n said to go try it and phone text him afterwards to see how it went. Lol. Dug out bike and tried it on the road. Bear in mind the only bit of straight road I have round here is about 100 yards long single track with a blind bend over a blind crest each end.

Wound it up in first gear wheel spinning everywhere on loose shingle road and glanced down to see couple psi on boost gauge. Had another run at it other way n saw 3-odd psi before I had to lock up front end on gravel road before went off the bend/hill at other end. Didnt get right up rev range, or gears but enough to see its boosting. Was fairly shifting on such a small road anyway and just about missed the corner. Fair drop at edge too. Lol. So yeah building boost. Confident if get bigger bit of road it'll be hitting peak torque of 7psi. Had plenty more to go by feel of it.

Revved clean onto boost with no stumble at all. Just built revs like normal but quicker. Nice and smooth with no carb hiccups or owt. Was well chuffed when got back.

During the week Im going to weld up a brace to support back end of bike and strap it down to ground so I can run it in gear safely. Stick in higher gear and wind on slowly applying some back brake to load it and try set boost limit close as I can, then its road testing really. Insured as of couple days ago as swapped insurance over from my ninja project bike thats getting sold on completion. Get it up town for an mot, etc.

Long weekend at it but paid off with that one little test run. Well happy here.
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  #346  
Old 08-08-2011, 08:17 AM
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Cool as, mate!
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  #347  
Old 10-08-2011, 08:08 PM
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Cool as, mate!
Yer pretty damn happy bud. Been a fair old slog to get this far but very happy at moment. Not a bike I ever thought I'd ever have a chance of owning and certainly not building. Has given me a huge boost in confidence in my abilites this project.

In a couple of years I'm aiming to build something REALLY out there and special from literally an engine block upwards and make everything for it by hand from scratch. Been drawing it on CAD for last 6 months or so from an idea thats been in my head for 10+ years. Just doing final ray traced renderings of it. Its an utterly bonkers custom. Dunno how to describe it apart from `out there`.
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  #348  
Old 10-08-2011, 08:10 PM
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Got some oil locally. They only had 3ltr, but luckily had an unopened 1ltr at home. Engine fired up first touch of button and even the choke worked normally as it sat there on tickover warming up. Didn’t expect everything to be so user friendly standard bike-ish from cold. Not complaining though as will make bike easier to live with.

Flushed out contaminated oil, put in new stuff. Couple hundred ml of old stuff kicking around in passageways and in filter, etc but nothing to worry about. Fired it up again and smoking out of turbo problem is back to normal. Very slight mist in air like it was before. Nothing to worry about. Can live with very slight smoke now n again. It’s virtually nothing though again so that’s that problem sorted.

Went round bike sorting few odds n sods and checking nothing worked loose anywhere. Sodding little pin on back brake lever at pivot to master cylinder has vanished in test run other day. Only held in with crappy split-pin so must have pinged out on road somewhere. Hey ho replaced it with decent bolt and nyloc nut.

I chipped petrol cap at weekend when dropped a spanner out of my mouth ( twat, I know, I know). Whipped that off. I also caught the end wheel on my lathe with boost gauge cowl too when putting bike away at weekend (double twat). Only took an hour to sand/paint/clearcoat the two pieces though so no problem. Just wanting the wee bits right before I’m too busy riding to polish. Lol.:-




Went to fire it up next day and fired up fine then dropped to 3 cylinders, to 2 cylinders then cut out. Couldn’t hear normal `old man peeing` trickle of petrol return into tank from pump neither. Bugger a problem, then opened tank and realized I was outta petrol. Does tend to help. Lol. Grabbed couple jerry cans from village today though.

I’m away in the next few days on a ferry over to the mainland with my trike for its mot, but early next week I’m going to make time to get the bike out for some further testing now I’m caught up with work, etc. Some nice sunny evenings at the moment to take advantage of. The bridge/causeway linking my island to main island is 5 minutes away, and is almost ¼ mile long, die straight new tarmac with good visibility both ends and dual lane too so bit more space to open it up safely.. Perfect for testing purposes. lol
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  #349  
Old 10-08-2011, 08:24 PM
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There's a straight bit of road where you live?
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  #350  
Old 17-08-2011, 09:00 PM
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Got new plugs through post. Just put em in. WOW. What a difference. First touch of button startup, hot starts fine now too unlike before. Crisp throttle and oil mist out of turbo reduced even more. Must have been some unburnt fuel in cyclinders too. Holding throttle at 1/2 revs even theres next to sod all coming out of exhaust and I'll be riding at below that most of time. Sorted. Revved bike a lot and ran it in shed for 10 mins. When turned off there was a very light film of oil on inside of exhaust and that was it. Sort of a greasy food finger residue on surface (i.e. sod all). No black oil like before so well chuffed with that.

Tickover jumped up to 2500 revs tho. lol. Wound out adjuster on side of carbs but not making much difference. Took carbs off several times and fitted a stronger return spring, etc but no difference. On about the 4th stripdown I found the problem. Carb balance adjusters miles out so cylinders 1&2 had theyre butterflys open by 0.5mm or so at tickover therefore raising revs. Balanced carbs by hand using gaps trick. I’ll borrow vacuum gauges when get a chance, but tickover rock solid at 1000 rpm or so, so not far off.

Started it bout 20 times though when out there n firing up straight off button hot or cold. Also wound out idle mixture screws some 6 turns over stock to richen it up on tickover after reading setup tips on OSS. Firing up lot easier as a result so deffo helped.

TEST RUN…………

Sunny-ish this afternoon after work. Few damp patches n puddles about but not too bad compared to storms of last few days. Wasn’t about to waste opportunity.

Took it a few miles to the bridge/causeway as only straight bit of open tarmac for miles. Opened it up and built to 3psi of boost by 1/3 revs or so real easy and smooth. Wouldn’t go beyond that though. Sat rock steady at about 3psi from less than ½ revs to max revs. Slight flat spot in carburetion when tried to build boost in too high a gear at like 30mph but pulls through it. Flat spot not noticeable though if in right gear. Just wanted to see what it would do if tried it. Lol.

I set the wastegate up originally very roughly when was rebuilding the turbo using my airbrush compressor to get it opening early and being fully open at 7 psi roughly. Obviously that doesn’t equate once up n running due to pressure drop through intercooler n all the pipework, etc. Looks like I need to wind the wastegate adjuster out couple turns at a time till hitting my 7psi of boost. Building boost at low revs easy though so no reason to doubt it. Bit of adjustment is all really.

Other than that engines running at ok temp, no leaks. Bit fookin loud till get up the gears a bit. Might make up some small baffle plates to stick in exhaust to take the edge off it.

Apart from that its all fine. Front brakes surprisingly good compared to 1st generation bandits, but bit bigger piston size. Bike came with brand new discs and sintered pads though which probably helps. Lol. Back brake kinda useless due to length of swingarm as no weight on it. Locks up real easy!

Handles alright too. Cant throw it around like my Harris, but not too bad. Just a slight adjustment of riding style really. Rides fine. Got my Harris there for corner carving anyway as bandits a straight line tool.

Some of looks I got off folk on pavement and in cars coming other way was classic. Don’t think they knew what to think. Just sort of stood there with jaws open. Lol.

Gradual upping of boost is all really. Going to brace up numberplate bracket a bit to make it a bit stronger as flexed a fair bit when got up to speed. Apart from that really though I think I’m ready for booking MOT n getting some miles in. Carry a spanner with me till got boost level set right. ;D
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  #351  
Old 18-08-2011, 09:15 AM
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There's a straight bit of road where you live?
Strangely enough it's about half a mile long. A Natural drag strip.....

Good to see you have the bike up and running, Harris.
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  #352  
Old 22-08-2011, 12:54 PM
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Due to an unplanned absence, I had forgotten where I was up to on this thread, so I started right back at the beginning, what an epic, epic thread, the stuff of legend and I can heartily recommend that others do the same.

An out-fuckin-standing read and an out-fuckin-standing build.

Well done mate, crackin' job.

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  #353  
Old 03-09-2011, 11:04 AM
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Well had my photoshoot on Thursday. Just around about my house same as last few features. Stunning scenery so handy as a backdrop.

Took about 2 hours to get the photos taken, but the sun came out as soon as Simon Everett arrived and started raining as soon as he left so got lucky with the weather. Big thanks to Claire for doing the modeling for me. Poor lass was frozen solid by time we got done. She hadn’t done bike photoshoots before, as done clothes/catalogues/tv work before, but tried her best and the photos should look good I reckon as did a lot of poses n angles with her and bike and bike on its own, etc. Only one or two riding shots with me on it thankfully as I hate being in front of camera. Besides Claire is a lot better looking than me on the bike. Lol.

Getting some photos on cd of the photoshoot, so I’ll stick up a couple of pics on here when get the ok from MDM. He might want to hold them back till feature comes out, but might be able to stick up a couple teaser photos before then for you all. Failing that you’ll all have to keep buying Streetfighters magazine and wait for the feature. Lol.

Going to book the mot as soon as I can and get her on the road properly. All insured and ready to go though. Turned the boost up couple of turns the other day and running/boosting fine at moment. Just need some road space to stretch its legs a bit. Run up town to mot station will be good test run though.
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Old 03-09-2011, 11:07 AM
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Good to see you have the bike up and running, Harris.
Cheers bud. And thanks to anyone else for words of encouragement, etc along the journey. Builds been on a few forums from the beginning following the ups and downs of it all. Kept me motivated throughout knowing that if I downed tools n gave up Id get moaned at by people. Really helped believe me.
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Old 03-09-2011, 11:13 AM
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Due to an unplanned absence, I had forgotten where I was up to on this thread, so I started right back at the beginning, what an epic, epic thread, the stuff of legend and I can heartily recommend that others do the same.

An out-fuckin-standing read and an out-fuckin-standing build.

Well done mate, crackin' job.

Cheers bud. Its a long old read for sure. lol. Should have wrote a book I wrote that much during the build. I've enjoyed it though throughout and plan on detailing my next big build in couple years time after Ive finished the ninja and rebuild the Harris, etc.

Its a top secret biggy and Im aiming high. Going to try get a magazine on board with that build though to help finance it. Only looking at £1000-1500 to build it I reckon as making literally everything from junk or parts I already have including the engine.
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Old 05-09-2011, 10:51 AM
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..... Can't wait.
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  #357  
Old 30-06-2012, 05:14 PM
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Location: Isle Of Harris
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Not updated for a while. Things have been stressfull here so slipped out of order of importance tbh.

Terminal illness in family to deal with which has been ripping my family to bits last 6 months or so. Add on top of that straight 70+ hour weeks with commission work n just couldn’t find motivation to build/update about what Im doing.

Been trying to spend less time in garage and more time indoors to see us through it so progress has been slow.

Liked Viz`s turbo chop thingy layout n decided to go similar route.

In pieces again.:-



Carefuly split open end clamp with hammer n screwdriver. :-



Flipped one end round and closed it up again.:-



Made a bracket to mount oil cooler up top, and new bracket to mount intercooler down bottom of front. Bit of tube shows where new Yantosh header log manifold will fit between the two. Intercooler is several inches narrower than oil cooler so wont grind on tarmac like cooler guard did when leant over. Lol.:-



Got busy with grinder and hand file, etc and made this chunky alloy bracket to support dump valve.:-

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Old 30-06-2012, 05:15 PM
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harris harris is offline
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Continued.............



New LHS layout of plumbing.:-




My mate Steve up town found a engineering place that made oil lines for boats, etc. They chopped about my original oil lines and used the ends, etc off them to make new ones cheaply. Sump ends were modified to sit much closer to engine too for more ground clearance.



Steve also scored these for free. 90 degree adaptors for cooler end of hoses.



New front layout.:-



Little carbon fibre cover made out of section of and old damaged hugger. Covers rusty ugliness of turbo centre section a bit.:-

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Old 30-06-2012, 05:16 PM
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Continued........



Where turbo will sit on new headers. Yantosh is making endplate adjustable/clamp on so turbo will be swiveled to dead level instead of at angle like before. Should get rid of last of smoking.:-



Pipe exit into intercooler. Had to clock turbo body parts again to get it to line up.:-



Turbo tight against engine now so mucho narrower. :-



Top view to give an idea. Bout same width as bars. Only 3” wider than Z lump in my Harris. :-



Few pics with turbo stood on axle stand where it`ll be going.:-


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Old 30-06-2012, 05:16 PM
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harris harris is offline
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Location: Isle Of Harris
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Continued..............






Left over parts. Not generally good to have parts left over but happy about it in this case. Lol. :-



Just waiting on Mr. Yantosh having some spare time to make new headers up for it. Tig welded stainless loveliness with some sort of billet end swivel/clamp trickery. Lol

Also on the hunt for a B12 engine for it. A mate up town is building a hard up choppers wormburner chop. Stripped fair few bits off a cheap B12 he picked up for it. Decided he really wants a gsxr11 engine in it though so breaking the rest of B12. We`re discussing painting his chop in exchange for the B12 engine n carbs. Hopefully will come off. A mate Peter was running a B12/T25 combo successfully and kindly gave me his jetting setup, etc so could all work out well. See what happens.
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