Crofter985'S KLX650C supermoto build

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Crofter985

Hi,
I am just going to leave the engine standard for now, maybe a cooler plug but as little as possible. CR is 9.5:1 on the 93 KLX, so it will take a little boost before pre ignition starts. I just would like to get it running that's my goal for now. Then perhaps engine mods after. I have a dump valve, I think it will go next to the carburettor.

Did you use a pitot tube for boost reference?
Thanks

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Crofter985

This follows on to my question about the pitot tube.

Crofter985 klx650c supermoto build 120.jpeg (224.04 KiB) Viewed 6248 times

Is this like a pitot tube? It is bored through to the beginning of the "snail" of the compressor exit, I mean where the tube is at its smallest and goes on to widen out to the outlet aperture.
Not that I've been and seen everything but I've never seen this pressure take off used for anything other than the waste gate actuator pressure reference. Does anyone know if it's boost pressure or boost + or boost -???

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CR500XR650RNORWAY

This follows on to my question about the pitot tube.

Crofter985 klx650c supermoto build 120.jpeg (224.04 KiB) Viewed 6248 times

on my turbo tdo04 12t i dont have this pitot tube ,but i have made a pitot tube on a similiar area on my turbo. This is the place to use for preferece to the fuelregulator and the waste actuator. I have also a pitot tube for presure to the vacumechamber on the carb.

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Crofter985

Sorted a couple of bits on the turbo today.

Crofter985 klx650c supermoto build 121.jpeg (169.5 KiB) Viewed 6248 times

That's the oil feed adaptor (m12x1.5 to m10x1.25) shortened and you can also see the turbine outlet adaptor plate that my pal cut out of stainless on a CNC water jet cutter bed.

Crofter985 klx650c supermoto build 122.jpeg (152.53 KiB) Viewed 6248 times

Drilled and tapped two new holes.
There is 5bolts holding the compressor housing on now instead of four.

Crofter985 klx650c supermoto build 123.jpeg (232.2 KiB) Viewed 6248 times

This is in glorious upsidedown-o-vision, I thought the chamfer on the turbo inlet was a bit crap, hardly any, so I got the housing in the lathe and turned a 7 degree taper on the intake, that will perhaps fool a little more air into going into the engine.
Trouble is the compressor exit is probably worse and it's not easy to get in the lathe.
Have to have a think about that.

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Crofter985

Thanks HP, I think I will just go with that for boost reference then. I love a easy answer!!!!!!!

I am also going to take a boost/vacume reference off between the head and the carb for the blow off valve

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Crofter985

Here I've spaced the tank and seat up 15mm. Lots of reasons for this, mostly to do with space.
Carb is v close to tank, I have a CBR1000RR tank and pump, I need a little bit more clearance so I can cut the bottom out of the CBR tank and weld it into the KLX tank, I think this 15mm rise should do it.
I would like more room under the seat for the plenum and the water/meth tank, this will help with that. As the subframe will be cut off soon so new mounting points for the seat will have to be made anyway.

Crofter985 klx650c supermoto build 124.jpeg (214.79 KiB) Viewed 6248 times

I took the spring off the shock today so I could compress the shock to see where the tyre was going to come up to when the suspension is in full compression, this is another stage in the subframe build. I'm trying to put a lot of thought into the subframe. It's got a lot of things to do and I'll be really hacked off if I have to junk it half way through. I'm going to try to make up some cardboard mock up/templates next and then get the bits cut out for me.
I did a test yesterday on a bit of 1.2mm alloy, to see if I could weld it. I got a inverter mig for repair jobs at my business and it's the mutts nuts, it welded it no probs, the arc quality or stability or whatever it is, is really good but distortion is going to be a real problem on this thickness. 1mm 1.2 and 2mm are the choices available for locally available aluminium sheet. I think I'll have to go with 2mm and a bit of internal bracing, if I was to get up to 15psi that's a lot of flexing in a 4 litre vessel.
It probably won't be all that but you never know.?????? Wahahahahahahaha.........

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Crofter985

I missed your post there the other day, sorry. Yeh they got good figures out of that one. I don't think I'll get the same percentage increase. The stock KLX is only 45hp, if I could see 65-70hp I think it would be a lot of fun at that level of power/boost.

Once I get it running I will mess about with ignition, cams, porting, that kind of stuff, oh and I will probably try some kind of bottom end strengthening and welding. I've been advised that this is needed, CR500XR650RNORWAY has been running a turbo XR650R for many miles/hours and has advised me on a lot of crucial issues.

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Crofter985

I've decided to put oil return into the clutch housing, it's not so easy to weld the pipe in but it's going to make the piping easy and neat. So here goes.....

Crofter985 klx650c supermoto build 125.jpeg (216.63 KiB) Viewed 6248 times

The flat bit just inboard of the water pump is where I think it's going to be handiest, slipped off the cover and I took out the water pump drive. But I left every thing else alone.

Crofter985 klx650c supermoto build 126.jpeg (208.24 KiB) Viewed 6248 times

Then I turned a little stub of pipe out of a bit of bar. Drilled it, put recesses to get the hose to grip it better and then parted it off.

Crofter985 klx650c supermoto build 127.jpeg (188.83 KiB) Viewed 6248 times

Then I welded it on, I put a big bit of stainless steel flatbar up against the gasket mating surface to act as a heat sink, to help save the surface, if I had blown through there with the welder it would have been a real f-up. The welding was a disgrace, but as someone invented abrasive flap wheels for grinders I got it to look presentable instead of something out of a nursery school art exhibit.

Crofter985 klx650c supermoto build 128.jpeg (175.67 KiB) Viewed 6248 times

There we go, I raided the engine bay of a old car outside and found a bit of pipe with clips that when cut down fitted like it had always meant to be there.
Now it's all plumbed in for lube anyway, time for a test start, I can't resist it.

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Crofter985

Right I made two videos, having problems uploading the second one but here's the first one.......
[url]http://i1243.photobu...zps6xyrxb6j.mp4[/url]
Hope this video plays.

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Crofter985

Got the other vid uploaded.....

https://www.youtube.com/watch?v=0ZZdwnCrZ3A#t=10

You can see the oil lines easier in this video too.
It's a lot quieter than just a open exhaust. Subframe and plenum next.

EDIT... Wrong video last time.