Steve's Turbo KZ650

OnkelB, Wow thank you very much!!

It's very clear to me now how to machine a housing for the set of rotors I picked up on ebay.

Thanks again guys!

Steve

Yes-sir-e-Bob! We now have front turn signals too!

I know a lot of guys ditch the turn signals or replace them with little itty bitty led pods of some sort.
But I like the factory turn signals! They are Big, fat and heavy! Just like I like my...no no no....

But they do seem to just "fit" this old school hotrod I'm building.

This SR had them mounted on the handlebars as stock. I moved them to the lower fork clamp.
I did not have any long metric bolts so I retapped the clamp for a larger and beefier 1/2"-13 thread and used grade 8 bolts.
Then I turned up a couple of spigots for the turn signals to clamp onto and some beauty caps to cover the hex head. Everything easily clears the tank at full lock. .




I timed and tested the dyna 2000 ign and it works perfectly. Good strong spark. I mounted the ign box above the plenum box.



The seat is just resting on the frame. It snugs down tight to the frame and tank when bolted in. I seem to be having issues with the camera showing the correct color of the paint with the florescent lighting.

Steve

S_J_H wrote:

Yep it's a good little mill for small parts. It's work envelope should handle most things I'll want to make for the bike. I used it to make the plenum box. That was probably the largest thing I have used the mill for. It hogged out the 2"deep X 2.25" x 11" cavity from a hunk of 6061. I used this 2" reach 3 fluter-

Took a few hours to cut.

I installed the rest of the dyna2000 this afternoon. Wiring is my least favorite part of hotrodding anything but it has to be done.
I just need to time it and I can move on to the scavenge pump.
I don't suppose anybody has pics of a stock oilpump with the rotors out? I would like to see how the inlet and outlet ports are configured..
Steve

awesome work man!
for bike parts the work envelope does not have to be very big,the plenum looks very nice.
i saw where a guy over on cb750 used a cnc router to cut some triple trees outta 7075.kinda opened my mind about what cnc routers could do.

leon

Well progress slowed down for a while but I'm ready to get back to work now. :evil:
First up is get this oil scavenge pump built and operational.

This is the lower housing I machined to fit the set of OEM Kawasaki pump rotors and the 12V DC motor that will power it-
I did not model this beforehand and just made it "on the fly" so to speak.




I still need to machine the drive shaft and a teflon seal to complete the lower half of the pump assembly.I'll begin making those this evening.

The upper housing of the pump I have designed into main 2 parts. Part A is the port housing and part B the retaining or locking ring.
The advantage of this setup is that the port housing can be rotated in relation to the pump rotors to any position. This will allow flow rate adjustments and by rotating 180 degrees can reverse the flow without reversing the motor.
Might come in handy some day if I use the pump for something else..
I modeled the upper pump housing assembly in Solidworks. This is the second real project I that have used Solidworks to aid in the design.
I resisted learning how to use 3d cad or any cad for that matter since it just seemed like an awful lot to learn. But now that I understand better how to use the software I enjoy using it.
Ok, so here is a view showing the upper pump assembly and the crescent shaped intake and exhaust ports on the bottom side of the housing-



And I'm also trying to teach myself how to render a 3d model into a more realistic looking part-
This was my first real attempt at rendering using Photoworks rendering software.
I made the floor reflective so you can get a peek at underside of the assembly.


So now I just have to get my butt in gear and machine these parts and test it out!
Steve

awesome work steve!
i have resisted setting down and learning a new cad program as well,but can see the time when it will have to happen drawing closer.

keep up the good work and post all the pics you can.

leon

Fine job on the machining. Making your own gerotor pump? Okay, now I'm jealous! How about the electrical system? Are you sprucing up the stock alternator?

Steve - why did you decide to make your own scavenge pump rather than using one from the market? Looks cool! Keep up the progress.

Nice job Steve. Hopefully we can tempt you over to the dark side of 750 turbos one day

Hey thanks guys!

How about the electrical system? Are you sprucing up the stock alternator?

I have no plans to improve the alternator right now but I am aware that I may need to.

why did you decide to make your own scavenge pump rather than using one from the market?

I suppose mainly to save some money but I enjoy projects like this as well.

Lorcan, I have lurked around at 750turbo.com many times. Great site and bikes!

Steve

wow, great build and great machining skillz. thatnks for posting all this.....Joe

Amazing machine work there Steve, I'm glad stumbled on your post. I was looking for some ideas with turbo system for my KZ1000P project. Any updates on your project?

Beautiful build.