rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
Thanks for the kind words subaru2006 - sorry but no video so far, I have a digital video recorder so I may be able to shoot some footage this winter 
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
UPDATE November 10. - Making a card board template for a new turbo heat shield. Cutting aluminum sheet metal.
As my turbo header is different than the Powder Lites headers, my turbo header sets the turbo with the air inlet pointing straight forward. The small PL heat shield I bought did not fit on top of the turbo so I had to make a new one from aluminum sheet metal.
I started by making a card board template.
With a perfect fit on the template,
I was ready to transfer the template to a piece of aluminum sheet metal.
Next was cutting out the heat shield from the sheet metal using a die grinder.
When cutting was done I ground down the ragged edges of the heat shield using a file.
Cutting done.
It still has to be hammered into shape and installed in the sled. I'm debating with myself wether to use rivets or bolts and nuts when installing the heat shields. Bolts and nuts are way easier on removal, rivets are way easier on install hmmmmmm..... what to do?
As my turbo header is different than the Powder Lites headers, my turbo header sets the turbo with the air inlet pointing straight forward. The small PL heat shield I bought did not fit on top of the turbo so I had to make a new one from aluminum sheet metal.
I started by making a card board template.
With a perfect fit on the template,
I was ready to transfer the template to a piece of aluminum sheet metal.
Next was cutting out the heat shield from the sheet metal using a die grinder.
When cutting was done I ground down the ragged edges of the heat shield using a file.
Cutting done.
It still has to be hammered into shape and installed in the sled. I'm debating with myself wether to use rivets or bolts and nuts when installing the heat shields. Bolts and nuts are way easier on removal, rivets are way easier on install hmmmmmm..... what to do?
kinger
VIP Member
Knowing you...better bolt it
nytroERrider
Expert
kinger said:Knowing you...better bolt it
I second that!
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
UPDATE November 11. - Fitting the Powder Lites heat shield, part 2. Hammering the new turbo heat shield into shape.
I finished off fitting the PL heat shield and drilled a hole to bolt it on using the middle stock heat shield treads. It took some serious cutting and grinding before it fit perfectly and I were able to bolt it in place permanently.
Finally I got the heat shield the way I wanted to.
The heat shield fits perfectly around the turbo without touching the turbo or downpipe.
I tested by installing the gas tank to check that it would fit with the heat shields. It did by a huge margin. I should not get any problems with too much heat at the gas tank. I will install shielding materials on the gas tank anyway.
Plenty of room between the heat shields and the gas tank
Next I started bending the new heat shield, to go over the turbo, into shape. This one also gave me a hard time cutting, grinding and bending before I was happy with it.
It fits nicely on top of the turbo without touching the turbo housing. I also closed the hood to check wether the hood would touch the heat shield, it was a close fit but no problems encountered.
I still have to secure the heat shields to the frame and to each other. I went with bolts instead of rivets, much easier on removal. I feel bolts are the only way as the heat shields have to go on and off numerous times before final install. Guess I had the heat shields on and off about 100 times today.
I finished off fitting the PL heat shield and drilled a hole to bolt it on using the middle stock heat shield treads. It took some serious cutting and grinding before it fit perfectly and I were able to bolt it in place permanently.
Finally I got the heat shield the way I wanted to.
The heat shield fits perfectly around the turbo without touching the turbo or downpipe.
I tested by installing the gas tank to check that it would fit with the heat shields. It did by a huge margin. I should not get any problems with too much heat at the gas tank. I will install shielding materials on the gas tank anyway.
Plenty of room between the heat shields and the gas tank
Next I started bending the new heat shield, to go over the turbo, into shape. This one also gave me a hard time cutting, grinding and bending before I was happy with it.
It fits nicely on top of the turbo without touching the turbo housing. I also closed the hood to check wether the hood would touch the heat shield, it was a close fit but no problems encountered.
I still have to secure the heat shields to the frame and to each other. I went with bolts instead of rivets, much easier on removal. I feel bolts are the only way as the heat shields have to go on and off numerous times before final install. Guess I had the heat shields on and off about 100 times today.
nytroERrider
Expert
Man this thing is looking great. Its like a tv show to me, evertime i look on this fourm i look at this to see if there is any new pictures and installs you have done. Great Job!
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
UPDATE November 12. - Last adjustments to the heat shields. Driling out bolt holes for installing of the Powder Lites heat shield and the new heat shield.
Today I did the last adjustments to the heatshields before drilling out the bolt holes for installing them to the frame.
For the top heat shield I installed a set of 6 millimeter threaded rivets into the deltabox frame using a special bolt and nut made for the install. The threaded rivets are very similar to what you will find all over the RX-1 and Apex frames.
One of the last mockup installs, mostly done.
Covered a small hole where radiant heat would have heated the lower steering column plastic bushings. Bolt holes for the top cover drilled and bolts and nuts installed.
Testing if the hood still fits with the heat shields installed, puhhhh it does
Installed the turbo and downpipe again. Final mockup install will be done next time out to check if all bolts can be installed with the turbo and downpipe in place. Heat shields done, ready to final mockup install.
I have very little left to do before reaching a standstill in lack of parts to install. I need a load of track clips to fully clip my track before installing the drive train. I need the oil return kit and oil line restrictor before I can permanently install the turbo and downpipe. I also need the stage 3 intercooler.
What I can do is finding a place for the air filter, and start mocking up the air filter hosing. I can also start cutting out the seat to make it fit on top of the REV gas tank.
Gotta remember to order a set of brake pads, I have 13800 kms or 8600 miles on them, they're not completely worn out but I will change them anyway.
Today I did the last adjustments to the heatshields before drilling out the bolt holes for installing them to the frame.
For the top heat shield I installed a set of 6 millimeter threaded rivets into the deltabox frame using a special bolt and nut made for the install. The threaded rivets are very similar to what you will find all over the RX-1 and Apex frames.
One of the last mockup installs, mostly done.
Covered a small hole where radiant heat would have heated the lower steering column plastic bushings. Bolt holes for the top cover drilled and bolts and nuts installed.
Testing if the hood still fits with the heat shields installed, puhhhh it does
Installed the turbo and downpipe again. Final mockup install will be done next time out to check if all bolts can be installed with the turbo and downpipe in place. Heat shields done, ready to final mockup install.
I have very little left to do before reaching a standstill in lack of parts to install. I need a load of track clips to fully clip my track before installing the drive train. I need the oil return kit and oil line restrictor before I can permanently install the turbo and downpipe. I also need the stage 3 intercooler.
What I can do is finding a place for the air filter, and start mocking up the air filter hosing. I can also start cutting out the seat to make it fit on top of the REV gas tank.
Gotta remember to order a set of brake pads, I have 13800 kms or 8600 miles on them, they're not completely worn out but I will change them anyway.
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
nytroERrider said:
nytroERrider - Thanks for the kind words, comments like that adds to my inspiration, making me wanna go out again right away working on the sled all night
Thanks buddy for a nice deal! I closed the deal during the night shift. I guess you can afford some new brake pads now -LOL.
You "boost addict/WOT addict" - 13800kms without changing brake pads - I guess your friends have seen your tail light most of the time when you guys are sleeding.
You "boost addict/WOT addict" - 13800kms without changing brake pads - I guess your friends have seen your tail light most of the time when you guys are sleeding.
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
Hahaha thanks for the business Yeah I have already bought a set of pads, comparing them to the old ones I guess there's life left in the old ones for about 20000 kms before they wear thru to the steel.
Gotta check my bank account
Your turbo package will ship any day soon.
Yeah I have already bought a set of pads, comparing them to the old ones I guess there's life left in the old ones for about 20000 kms before they wear thru to the steel.Gotta check my bank account
Your turbo package will ship any day soon.
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
UPDATE November 13. - Last adjustments to the heat shields, part 2. Mockup install of turbo, downpipe and heat shields.
With the turbo and downpipe installed I started to install the heatshileds. Without the turbo and downpipe in place the heatshields fit perfectly, not so with the turbo and downpipe installed. I was not able to get a bolt thru the upper holes due to very tight clearance between the turbo and the RH side of the heat shield. To fix this problem I drilled out a 9 millimeter hole in the PL heat shield and installed a threaded rivet in the hole, now I was able to install the bolt from the outside in attaching it to the treaded rivet, problem solved. I was now able to install all bolts holding the heat shields in place.
I changed out the bolts on the LH side with longer ones and added washers. I will lock down bolts using lock washers.
Mockup install done, all parts fit nicely
This is how my brake pads looks like after 13800 kms or 8600 miles, some life left but I will change them with a set of new ones, keeping these one as emergency spares.
New brake pads.
The last work I started today was working on routing the 3" hose from the turbo inlet to the air filter installed in the nose cone. After studying it carefully I have found only one option (without cutting a hole in the hood) that is viable, placing the air filter in the nose cone. I had to grind off a little more from the hood and headlight pod to clear the 3" hose. I will run a 45 degree 3" bend down to the left, then turn back straigth forward on the side of the IC hose, past the IC and down into the nose cone. I will be back with pics when I have nailed it and started the install.
With the turbo and downpipe installed I started to install the heatshileds. Without the turbo and downpipe in place the heatshields fit perfectly, not so with the turbo and downpipe installed. I was not able to get a bolt thru the upper holes due to very tight clearance between the turbo and the RH side of the heat shield. To fix this problem I drilled out a 9 millimeter hole in the PL heat shield and installed a threaded rivet in the hole, now I was able to install the bolt from the outside in attaching it to the treaded rivet, problem solved. I was now able to install all bolts holding the heat shields in place.
I changed out the bolts on the LH side with longer ones and added washers. I will lock down bolts using lock washers.
Mockup install done, all parts fit nicely
This is how my brake pads looks like after 13800 kms or 8600 miles, some life left but I will change them with a set of new ones, keeping these one as emergency spares.
New brake pads.
The last work I started today was working on routing the 3" hose from the turbo inlet to the air filter installed in the nose cone. After studying it carefully I have found only one option (without cutting a hole in the hood) that is viable, placing the air filter in the nose cone. I had to grind off a little more from the hood and headlight pod to clear the 3" hose. I will run a 45 degree 3" bend down to the left, then turn back straigth forward on the side of the IC hose, past the IC and down into the nose cone. I will be back with pics when I have nailed it and started the install.
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
Got email for Powder Lites last nigth - my parts are ready to ship, paid for the parts and got a tracking#. Stage 3 IC has been built and the rest of the turbo parts needed has been shipped, I'm a happy builder hahaha.
It's turbo time in rxrider's turbo garage.
It's turbo time in rxrider's turbo garage.
fxnytrortx3
Expert
wow great job on everything rxrider. I love looking at this thread. All of the pictures and If i was going to put a turbo on my sled i would come to this thread to look at how you did it.
nice job
darren
nice job
darren
rxrider
Jan-Ove Pedersen
- Joined
- Apr 25, 2003
- Messages
- 7,355
- Age
- 59
- Location
- Lakselv - 70N & 25E
- Country
- Norway
- Snowmobile
- 2014 Phazer XTX, 2013 Phazer RTX, 2008 Apex RTX, 2007 Warrior, 2006 Attak
Thanks Darren - fxnytrortx3
I have tried my very best documenting the upgrade process I started a few years back. I have covered most of what you will encounter building a turbo sled except the cylinder head job slotting cam sprockets, checking valve clearance and lowering compression, that job was done before I had a digital camera to take pics. It will be documented if I'm ever going to take my engine apart sometime in the future.
Jan-Ove
rxrider
I have tried my very best documenting the upgrade process I started a few years back. I have covered most of what you will encounter building a turbo sled except the cylinder head job slotting cam sprockets, checking valve clearance and lowering compression, that job was done before I had a digital camera to take pics. It will be documented if I'm ever going to take my engine apart sometime in the future.
Jan-Ove
rxrider
If I send my send over to you will you do the same thing to it. LOL
Damn that sled is looking nice you have put a lot of time and money into it.
Damn that sled is looking nice you have put a lot of time and money into it.
