Another Custom-Turbo Nytro

[Omega_5]

if your bends dont have any sharp angles or edges on the piping(smooth walls on inside making it look like a continiously bent pipe and not two pipes welded together where there is a corner on the inside) I dont think efficiency will be much of a problem. If anything it will be a small hp difference. Only thing that will give you a big difference is making your own mapping without a dyno compared to the company that has the ability to dyno after every change.

That's very true. Good craftmanship is a good majority of the build. Nice internal seems, no burn throughs, flush joints... they make or break any air flow system; exhaust or intake.

The other big part about building your own system is know what you need. Proper sizing of a turbo, knowing what volume of IC you need, knowing where to route the piping to minimize bends or cuts/welds. It all adds up to the perfect system.
For first time builder, it's trial and error... but after a seeing a few builds you kind of pick up on what you need to get the job done.


And you're very right... most companies have the advantage of owning or having access to a dyno. It makes the initial tuning of any engine that much easier. It also allows the tuner to not require specialized mobile equipment; it's kind of hard to carry a laptop around while you're out ripping up a powder covered field.

just to stick my two cents in here, there are many people out there, myself included who want to build their own turbo setups. Yes we all know that it may not be as good as the kits you buy commercially but everyone starts somewhere. Eventually through our own testing we may have a setup that is as good if not better than a commercially available setup. Maybe it wont work, but we take that risk. Thats how this technology will get better, trying new things.

On top of this I have not added up everything I spent on mine but I had a turbo from a 2 stroke application I already had and I bought some parts used. I will have less than $1,000 invested. I appreciate the info Omega5 is posting and it is giving me ideas for what I want to do.

I will get off my soap box now, haha.

I am really interested to see how this works when it is done. Especially the RB3.

I agree with what you said there. We do take a risk in building our own turbo kit. But we do have the advantage of customizing it to our specific needs. It's part of the fun.


TJC, I should also clarify, I'm actually using the new Rapid Bike Racing. From what I've read, and what Mike (at Powderlites) explained, it's like the RB3... but faster and more versatile.



On a side note; I know I'm new to forum and all, but if anyone reading wants some pointers on turbo kits and such, I'm more than happy to share some experiences or information, whether it be from this build or past projects.
I've learned a lot of sled specific things for this build from lurking here for nearly a year... and I'd like to give back to the community however I can.

 

[Omega_5]

I didn't get a whole bunch done this weekend, as I had my company Christmas party on Saturday night (which meant I was a write off for Sunday).

I did manage to get the oil and coolant lines ran, though.

The coolant lines are taken off from the throttle body heater.
The oil supply is taken off from the M8 port at the front of the head. Oil return is down on the right case.


I had some extra time, so I decided to work with tucking the brake light cables. I used some brake line, and bent up a conduit tube that will run in the tunnel.

I threaded the tube on each end, so I could use a nut to secure it above the tunnel. I'm planning on using cable clamps to hold it on to the tunnel.

 

[tjc]

did you opt for oversize injectors or a rising rate fuel regulator?

I like the idea with the wires for the light.

 

[Omega_5]

did you opt for oversize injectors or a rising rate fuel regulator?

I like the idea with the wires for the light.

I'm taking baby steps with this one.... 100% stock fuel system for now.
If I feel like I need more power, I'll be shimming the head, and jumping up to a larger set of injectors. I imagine that will happen next season, when I upgrade the track and drivers as well.

 

[tjc]

I see are you high elevation, I have heard at sea level (like I am) the stock fule system is not good for more than 6 psi boost. I think I read you are going to 7-8 PSI?

 

[Omega_5]

Where I'm located is about 2200ft, my riding areas vary between 100ft and 2500ft.

I'm kind of stuck with a minimum of 7.1psi, as that is setting of the wastegate.

From what I've figured, I'll be right on the edge with the stock injectors. Assuming a .6 BSFC, and stock rail pressure being 46.1psi; I figure they'll go static at around 8500-8600rpm. If I need to, I've got no problem clutching it back to a lower rpm.

 

[tjc]

http://www.youtube.com/watch?v=rogCn4AJ ... re=related

I did this to my wastage on the mitsubishi turbo. Went from 12 PSI to around 5 or so.

 

[Omega_5]

http://www.youtube.com/watch?v=rogCn4AJYsY&feature=related

I did this to my wastage on the mitsubishi turbo. Went from 12 PSI to around 5 or so.

Interesting. I've heard of modifying the internal spring, but never adding an external spring.

Thanks for the link!

 

[Omega_5]

My exhaust donuts came in from Sledtoyz yesterday, so the exhaust went together last night.

I wrapped part of the tube near the head in order to control heat. It's not much, but every little bit counts. Copper donuts on as well.

I also added some fiberglass wrap to the outside of the heatshield.

The backend of the sled is pretty much finished. Oil pump mounted, oil and coolant lines on, charge piping on.

 

[Omega_5]

Another lazy weekend.

Got the exhaust dump finished up.

I also added another piece of heat wrap to the shield. I felt the gap at the tunnel wasn't very good.

I also got the vacuum lines ran, and charge piping all put together and pressure tested (as a one unit). No pictures, though, as those would be pretty boring.

BTW, TJC... I did that wastegate mod that you posted up. It works great. I dropped the opening pressure from 7.1psi to about 5.7psi.

 

[tjc]

nice glad to hear it.

You have snow yet? Nothing here but Im anxious to get mine going.

 

[Omega_5]

Nothing here either. And the forecast doesn't look to good either.
I'm getting a bit worried, cause usually during the Christmas break, we plan a bit snowmobile tour. I don't think it's going to happen this year.

 

[Omega_5]

Lots of progress this weekend.

Finished up the brake wire tuck.

Block heater installed

MTX HE installed
(sorry, no picture)

Exhaust dump installed

Intercooler installed

Charge piping installed

I just have to take care of some oil restrictor issues, then it's time to assemble it all.

 

[Omega_5]

More progress.

Fixed the oil issue.
It ended up being related to a leak. On of the AN fittings wasn't seated quite right.

Started assembling.

And... the brains of the show

I am having some issues with the RapidBike software though.
The RBR is supposed to be fully adjustable by the end user, kind of like the RB3 pro kit. However, it's limiting me to 30 in each cell, like the old lite software.
I have Dave and Mike at Powderlites looking into it. Apparently it might be an issue on DimSports end. Dave mentioned that he'd try to find a fix for me in the next few days. Awesome service!


Also, I while everything was still apart, I decided to take care of some maintenance. Changed the oil, replaced a broken e-brake cable, installed a 4th wheel kit, and changed the slides.

I also installed a shockwave helix, and checked the specs on the secondary. I'll try to remember to get some pictures of the shockwave.

 

[tjc]

nice, it wont be long.

what bov is that?

where did you end up wiring the oil pump into? same wire as the fuel pump?