new turbo setup : KawiForums.com Kawasaki Forums: Kawasaki motorcycle forums

aussie_636 · 10-22-2010, 12:34 AM

i started making up a new manifold, i had my bike turboed a few months ago and rode it around for a while but the exhaust manifold warped a bit and had a tiny leak and the inlet manifold also split and was leaking boost, and when i pulled it off i found alot of oil in the intake side piping....thought maybe the seals were bad of the scavenge pump wasnt upto pumping the oil....

but i had been thinking about it and i think the oil problem was because i didnt have a check valve so whateva oil was left in the motor would drain through the turbo and because the scavenge pump is off it just backs up was only about 2inchs of hose between the pump and turbo for the oil to back up in.....and the bike leans to the left when its parked so think thats why the oil was in the intake side of the piping, because it never blew any smoke on the exhaust side when riding....

so try no. 2

this time i am tryin to make the manifold a little better different flange that shouldnt warp and will give it some bracing and also try make it flow a little better then the last one, now i have some more skills should be better.

intake i will make it out of bit thicker alloy and actualy buy some decent alloy, last time i just used an old sign and it was weak as piss....

heres a pic of my old manifold and new one i started today

tryin to keep turbo roughly in the same position as before so can use same oil and water hoses and intake piping

punksrfr · 10-22-2010, 01:45 AM

It looks a lot better. What are you using for the exhaust seal flanges? The header flange looks to be a good piece.

aussie_636 · 10-22-2010, 05:05 AM

it was just a peice of 2in x 12in half inch thick flat bar and i just milled it either side, im going to bolt it to a jig that i will make from the other manifold so i get the turbo flange in the same place, so that should keep it flat then ill just face it after and also shape it a bit so its not just rectangle bar....ill cut out a gasket from stainless sheet or copper or something so it will just be like a car manifold that bolts up flat.....the other one i used the bits from the stock headers and the copper rings but when you do it up its not even pressure and it sorta is bending the flange around the copper rings if you know what i mean....

you can see the rings i turn up on the cnc that step down from the bends to the flange thats so i can get the nuts on cos the piping is a bit large the next side down is 1inch which is to small....i just knocked the no 1 and 2 bends off that i had tacked on cos i couldnt get to the nuts at the bottom so will have some 45deg bends then the 90s

heres a pic of the first one i made and where it leaked from, it was a bit on the gay side for flow also....

i was thinking about spinning the turbo around so the boost side faces up and exhaust goes out left side but its just no room and i have already relocated my fan to right side so would have to change that back over

punksrfr · 10-22-2010, 12:53 PM

Here's a little inspiration... this is one of, if not the best turbo manifold fabricators in the world.

Why do NLR headers cost more? - Psychobike.com - Motorcycle Drag Racing Headquarters

Turbo Headers - Psychobike.com - Motorcycle Drag Racing Headquarters

DH's Turbo kit - Psychobike.com - Motorcycle Drag Racing Headquarters

whitehendrix · 10-22-2010, 09:06 PM

god damn those are some fuckin sexy headers on psychobike. lol
i am back to square one now as well. the headers i have are titanium

aussie_636 · 10-22-2010, 11:14 PM

yeah pretty sweet, lol at there lathe tho, ill have to take some pics of the machines i get to work with...

how come bikes use spigots that go into the head and cars use just flat plate that bolts to the head? i always thought it was just so its a perfect flow for the gas, on the car you can bolt it up on the piss and might overlap the holes unless its dowled....???

punksrfr · 10-23-2010, 11:08 AM

The spigots are used to port match the header to exhaust port, just provides a straight shot for the exhaust gases to flow. Plus it gives a solid area for sealing the header to the head.

poofbegone · 10-23-2010, 06:34 PM

Good luck my friend. Fabing is always time consuming due to the issues of making one thing fit with out interfearing with another. But you know this so take your time and it'll come out better in the end. Besides the end results are always outstanding when your talking turbos. Hey maybe your headers can turn out like the ones from NLR. lol, jk

aussie_636 · 10-24-2010, 09:13 AM

punksrfr- yeah thought it was just so its always located nicely for better flow....

poofbegone-yeah the NLR ones look nice but theres nothing special about them, only difference mine will be offset because i cant have the turbo in the middle and im using mild steel not stainless, oh and my welds wont look like a robot did them lol(they looked pretty sexy). ms is cheaper and i can get it coated later if i want and will be just as good if not better then stainless....stay tuned ill make up a jig tomz, maybe i can start making some turbo manifolds and sell them

i might make a new flange and make some spigots just limited for space to get the wall thickness and still be able to get some nuts on the studs...dam factory never expected turbo to go on i guess

aussie_636 · 10-24-2010, 09:19 AM

on the NLR ones with the spigots, where do they actualy seal and do they have a gasket? to me it looks like they just slide in and seal on the face inside the port not on the outside, am i right?