Quote from: tb0lt on November 27, 2010, 04:26:00 PMCan't wait to see and hear this baby running.

You and me both

Quote from: saxman on November 27, 2010, 03:20:48 PM

Quote from: skirecs on November 27, 2010, 01:33:11 PM
cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine

Lots of electronics to fit in there

truth, i forgot about the fuel controller

Since your doing the bike for 1 up anyways, why dont you cut the seat. Make the tall solo seat cowl and stuff some of the electronics there, since space is at a premium?

Quote from: Chanse on November 29, 2010, 07:34:50 AM
Since your doing the bike for 1 up anyways, why dont you cut the seat. Make the tall solo seat cowl and stuff some of the electronics there, since space is at a premium?

That's the whole point of the cf seat cowl that I made. Allows me to cut away the seat material under it, freeing up a lot of space.

Quote from: saxman on November 29, 2010, 01:06:28 PM

Quote from: Chanse on November 29, 2010, 07:34:50 AM
Since your doing the bike for 1 up anyways, why dont you cut the seat. Make the tall solo seat cowl and stuff some of the electronics there, since space is at a premium?

That's the whole point of the cf seat cowl that I made. Allows me to cut away the seat material under it, freeing up a lot of space.

I think he means making it taller so you have more room.

Exactamundo

ah, gotcha. If need be, I will. I think if I were to go that far though, I'd probably just do a tail swap.



So time for a bit more technical of an update. Lots of pictures, but not super exciting.

Spent the afternoon in the machine shop, getting the throttle body taken care of.

After removing the extra butterflies and linkages, I was left with a couple holes in the throttle body like so.

Obviously as this is a pressurized system, I can just have a hole.

The idle valve mounts to the other throttle body, so I had to make mounts for it. There were supports in the throttle body casting left over, but they weren't drilled out.


So I made a set of plugs for the holes to be press fit in. I also made a pair of spacers to properly position the idle valve in the same spot it sits on the other throttle body.



The actuator on the idle valve presses on a lever coming off the butterfly valve from the other throttle body. I had to take a section of a rod, thread it so that it would screw on to the butterfly valve rod, then press the actuator for the idle valve to it.



And we're ready to go.

WOW! 

Crazy.

After hours of test fitting, etc... This is really the only place the intercooler will fit.


Pros: Fits nicely, isn't obtrusive, distance between the throttle body and the air tank is minimal

Cons: Airflow is meh.

I'll have to get creative with some ducting.

The pipes will tuck into the frame right behind my legs.


Found some room for the electronics.


I need to actually cut a recess into the seat for the ecu to sit in though.

My Lithium Ion batteries to replace the stock battery showed up as well. Fit perfectly right up against the intercooler. I'll start with four and go to eight if needed. They stack up so nicely.




Hmm, first time I've noticed the almost carbon fiberesque fabric the seat is made from.

Was it too big to fit up front. Where the oil cooler goes on the newer models? Just a thought.

Quote from: Chanse on December 03, 2010, 02:34:55 AM
Was it too big to fit up front. Where the oil cooler goes on the newer models? Just a thought.

yes it is. Too thick. The core is a good 4-5" thick. Would hit the forks during any sort of turning

Have you thought about a 'fairing' or headlight mount with the intercooler and piping?. I imagine it being similar to the ram air tubes on the 4 cylinder bikes.
Also, I think the smallest automotive intercooler is the old Saab 900's, which also has the inlet outlet on the same side. It could be a worthwhile alternative to look at.

Quote from: aaronjosephward on December 03, 2010, 09:53:14 AM
Have you thought about a 'fairing' or headlight mount with the intercooler and piping?. I imagine it being similar to the ram air tubes on the 4 cylinder bikes.
Also, I think the smallest automotive intercooler is the old Saab 900's, which also has the inlet outlet on the same side. It could be a worthwhile alternative to look at.

The Saab intercoolers are much larger than they seem. I did look at them.

considered mounting it up front, but I'm not planning on running the bike fully faired so the aesthetics aren't there, and having that long of a pipe from the intercooler to the intake is far from ideal. The nice thing about this placement is that the pipe length from the intercooler to the intake is really short.

Looks great, maybe make some air ducts that come out of the side to wrangle in some air? Of course they would have to be carbon fiber.

Quote from: redhenracing2 on December 03, 2010, 01:35:13 PM
Looks great, maybe make some air ducts that come out of the side to wrangle in some air? Of course they would have to be carbon fiber.

I will, sooner or later.

And here's how we make carbon fiber charge pipes from holiday supplies.

Part 1

Start with a styrofoam wreath of the appropriate tube diameter. I'm using a 1.5" diameter pipe here.


Must be polystyrene foam, not polyurethane!

Cut into sections and glue together.



Just like making an exhaust from u-bends.

Mock it up on the bike


Add some straight sections at the end.




To be continued this afternoon

Is it just me, or has the tank started to dull? The cowl looks dull too . . .  is it just dusty?

Quote from: redhenracing2 on December 03, 2010, 02:33:26 PM
Is it just me, or has the tank started to dull? The cowl looks dull too . . .  is it just dusty?

Both have been sanded down, but no finishing work done yet. They're on and off the bike so much at this point, they'd just end up getting scratched. I haven't even done a final trim on the cowl yet.

Looks pretty sweet. I swear I've seen a smaller inter cooler before..just can't remember where..

Cool beans. Are you gonna clear them or coat it in more resin?

Quote from: GI_JO_NATHAN on December 03, 2010, 02:44:02 PM
Looks pretty sweet. I swear I've seen a smaller inter cooler before..just can't remember where..

A buddy of mine with a turbo miata has a very small intercooler, but I think it's about the same as the one already being used here.