Turbo waste gate actuator

Tonight I adapted the turbo waste gate actuator to the exhaust system.

Another job fitting it in to the space available by extending the arm with a left and right hand threaded 8mm stainless steel bar and rose joint for a better action.

It is a pain in the bum all this stainless steel but the corrosion from the salt will be bad and if we can eliminate some it can only help on our return from Bonneville.      

 Three good friends testing Ralf Mitchell’s methanol Royal Enfield 250

The test went very well with a strong pulling Engine just a bit too strong for the clutch. But with a bit of adjustment at Ron’s house we will be up and running again.

             Ralf will have 2 Engines at Bonneville a methanol  and a turbo gas.   

swing arm

          Hi this is my swing arm from the Suzuki Hayabusa . This swing arm is not what it looks like it is full of lead and the total weight is 68KG I weigh 71KG just to put it in perspective. The purpose of all the lead is for traction on the salt. The salt has 40% les grip than tarmac and the wheel will spin in top gear no problem. In 2012 when my crew chief Richard Barks was on the salt breaking 2 land speed records the rear wheel was spinning at 180mph. have a look at you tube Richard barks Bonneville 2012 and listen to the revving engine indicating wheel spin also look at the track to see how ruff it is it’s not a smooth surface by any means. Any way back to the swing arm drill 2 holes under the back end of the arm tip it on end get an old copper kettle fill it full of lead, melt it very carefully as this is extremely dangerous,     and pour it in through the 2 holes,   this will take all day but at the end of the day you should have a 68KG arm.    Last thing is to look for cracks and heat distortion issues.    

Right side of Bike

                                                       Right side of the Bike to date

exhaust

This is 4 photos of my first exhaust as you can see it is a constant battle with room for all the parts.It is constructed from stainless steel 304 tig welded pre formed elbows sea
on eBay you can purchase 45 and 90 degree bends that mack the gob so much better.
all the pipe is 38mm for the headers and 75mm for the tail pipe with alloy flanges.
the bottom picture shows the thermal sensors and the Turbo tucked in tight against the oil filter and engine

This is the first exhaust I made,    not that easy as the exhaust gas must spiral up into the turbocharger so the pipes must be in the fireing order 1243 plus it all has to fit in between the engine and the radiator.

Exhaust manifold and Turbo . . .
Today I started on my second exhaust manifold for the 2nd engine. first I had to fit the Turbocharger to the Engine with a 20mm adaptor plate. This was a bit of hard work cutting milling and filing to get the right shape.
anyway it all fits now and the reason for a 20mm plate is the waste gate pivot that I will put in when I am  shore of the right place.

This photo is of the Turbo to intercooler tube installed on the bike with the dump valve mounted  and the sensor is tucked away on the inside out of the wind drag

This tube is from the Turbocharger to the Ice intercooler. I had to solder 2 tubes into the main tube one for the air temp sensor and the other to the dump valve. All this work had been finished and then I realized that the air temp sensor would create a lot of drag in the original position so today it was moved to the inner side of the tube

Just to give you a look at the Bike Hayabusa rolling chassis with a Yamaha 600cc thundercat Engine

This photo is of the 6th gear light that will reminded me that I am in 6th. it could be so easy to go flat out in 5th by mistake what you need to remember is there is nothing to judge your speed to get a idea
what it will be like the turbocharged Engine screaming your hear down and the view you will  see imagine if you sat on the beech looking out to sea absolutely nothing in your way just marker flags every 1/4 mile 

this light is activated through the Motec ECU and the gear position sensor this sensor is one we adapt from a standard  Yamaha neutral switch  and it will indicate to the ECU all 6 gears

the light consists of 3 neon lights 1 stainless steel tube a plug and some wire

you will have to excuse my spelling it can be bad but I hope you can work around this