rxrider's Turbo Garage - pics back, will continue

[rxrider]

No it won't end I guess, it's like aircrafts, the maint schedule is neverending. This time I hope my heat related problems will be a thing of the past And perhaps throttle response it going to be...hahahaha.. even better.

 

[Grimm]

Great job with adding that index. That helps a lot, avoiding searching page by page.

A very impressive thread.

 

[rxrider]

Thank you Grimm.
I'm glad kinger put me up with the idea to make an index, it actually works
The thread have helped a lot of people over the years so I'm very happy with it.

Jan-Ove

 

[rxrider]

Update December 13. - Working on the aluminum heat shields for the turbo, header and downpipe.


With all wrapping installed and the turbo blanket in place I have started the work of fitting the heat shields yet again. All the wrapping and the turbo blanket took some extra space so the shields didn't fit anymore, non of them. All shields have to be cut, hammered and ground to fit, the before pic.

I had to start by making the stock shield going in down at the header outlets fit the header. Some hammering and swearing later I installed it and tightend it down. Sorry no pic.

Next I started the work of making the rear Powder Lites heat shield fit. It was not even close, I have a few hours on it but it's still not installed yet. It has go on and off in a repetitive process cutting and grinding a little of the time until it fits snuggly in place. Here's a few pics from the process.

I also drilled out a few holes to install threads inserts to the shield to make for and easier install. Away with the bolt and nut, all I need now is a bolt and a washer.

With the changes done to the heat shields I had to make new holes for the bolts Swiss cheese comes to mind LOL.

I also installed a thread insert at the top of the shield in the delta box frame piece for easy install using a bolt and a washer. My shield will be firmly attached to the delta box frame this time, much better than last season. I have 4 bolts holding it to the frame now

Still have to fine tune the shield a bit before install, and I have the shield that goes over the top of the turbo left to install. I might not need it with the turbo blanket, but if I can make it fit I will install it for the piece of mind.


My sled is nowhere close to beeing but if it works I'm happy with it as I have sacrificed looks over functionality LOL

 

[kinger]

I'm glad kinger put me up with the idea to make an index, it actually works
Jan-Ove

Hey I'm good for something!

 

[rxrider]

Cause you are Both boost and skid pro you are, pretty darn toothin' good at it!!!

 

[rxrider]

Update December 22. - Working on the aluminum heat shields for the turbo, header and downpipe - part 2.


I'm pretty close to putting it all together. With the heat shields up there is only a little more insulation work to do. Here's a few pics of the heat shields finally in place.


The main rear shield needed a lot of work to get back in place, on and off a dozen of times before I had a good fit. I used the die grinder a lot, a file, metal saw on what not to get it done.

Finally I had it where I wanted it and mounted it to the deltabox frame.
I made a few new holes and installed new insert threads where needed. Very easy to install the way I have it now.

With the turbo blanket in place I also had to redo the top shield to make it fit. I had to bend the top shield to make it wider up top, thus I had to make new holes in the deltabox frame and heat shield as well for the new bolts and insert threads to go. I installed new insert threads to the shield to make for an easy install.

Some adjustments needed to make it fit.

The top shield in place and bolted down.

The turbo blanket fit nicely underneat the top heat shield.

Last piece was the shield for the side of the headers shielding off the secondary clutch. This was a bolt on piece

Next work is installing the charge tube and water temp wireing. Will continue after the holidays, like next monday I guess. Maybe earlier if I get the itch.

Merry Christmas and Happy New Year to all.

 

[BOUNTYHUNTER]

Sure wish I could see this stuff Jan, unfortunately no access


Enjoy your Christmas & New Year....Safe Sledding Homes

 

[rxrider]

What is it you can't access?

 

[rxrider]

Update December 26. - Installing charge tube and Vortech Race Bypass Valve. Installing piping for air filter. Installing Water Temp Gauge into gauge pod.


Last night I Got a few hours off from familiy- and Christmas activites. It's coming together, should be about ready to ride after early January.


I started off by installing the charge tube and Vortech Race Bypass Valve.

Hooked up the pressure/vacuum signal line to the Vortech, I have it hooked up to the carb boots (all 4 are T'd together).

I have changed the position of the air filter to get rid of the reduced cross area where the pipe had to be squezed flat to give room for the hood to close. I will now cut the hood even more to make room for the filter and to make a straingter path for the air to travel from the filter to the turbo.

Last thing was installing my water temp gauge to a pod. The pod was too deep so I had to cut the pod down for the gauge bolts to come out on the back of the pod.

This is how the water temp gauge looks like installed in the pod.

I marked the wireing coming from the pod so I would know where the wires goes when installing them.

I added Loctite to the bolt threads before tighten the nuts down. When the nuts was done I added Loctite to the threads above the nuts to help keeping the nut from backing off.

I will start working on mounting the steering column next time out. I will have to make a few mods to make the new billet block and oillite bushings fit my Wildchild steering column.

 

[standard]

Jan-Ove, sure is looking sweet.!

 

[rxrider]

Thanks buddy

 

[rxrider]

Update January 14. - Adding coolant. Installing hose clamps and securing air filter and piping. Cleaning and installing clutches. Installing steering column, billet aluminum mounting blocks and oillite bushings.


I have made some progress lately but haven't got the time to update the thread the last few weeks. This is what I have done since last update.


Mixing coolant consentrate with 50% water.

Ready to start adding coolant.

First I added coolant until the tank was full. Then I raised the rear of the sled until the air bleed screw at the rear rear heat exchanger was about level with the tank. The level in the tank sunk and I added coolant until it was full.

With the coolant cup full I opened the air bleed screw at the rear heat exchanger and let out air until all air was gone and tightened down the air bleed screw.

I lowered the rear of the sled and added coolant until the tank once more was full. Air was still coming out at the coolant cup, but now the air escaping came from the motor as all air was bled from the rear and running board heat exchangers. I added coolant a few more times before all air was gone. I'm going to check the level after the initial warm up, any air escaping will be coming out of the motor and escape into the coolant cup.


I have installed all hose clamps for the air intake piping and air filter.

The air filter and intake piping is secured with zip-ties.

My secondary clutche needed cleaning badly. Here's the before pics.

I used break cleaner on the outside and scrubbed them with ScotchBrite on the inside, the primary got a good scrub as well. Here's the after pics.

I used break cleaner to loosen up belt dust, then I used WD40 to get the shine back on the clutch cover.

The secondary clutch installed and offset was set to 15mm.

The side covers was installed.

Installing Wildchild steering column and new billet aluminum mounting blocks with oillite bushings. The upper block was a direct fit with the Wildchild steering column, no problem.

I was not able to install the lower block, the bolts were too short and the block didn't fit with the Deltabox Frame either. Some cutting had to be done on the frame piece.

Some cutting and filing was done to make more room for the block. Seen from the rear.

Seen from the front.

The lower block needed to be modified similar to the lower blocks that came with the Wildchild steering relocation kit way back.

Without the proper tools to do the work this is what it ended up like.

Before assembling the steering I added some light bike oil to the oillite bushings on the meeting surfaces between the bushings and the steering column.

I started the assembly of the steering column and handlebars by installing the lower block and oillite bushings.

Then I added the oillite bushings to the upper mounting point.

Next I added the blocks, spacers, bolts, washers and nuts.

Done.

I have made some progress and have very little work left before I can fire it up When the sun is back it's time to start testing the sled on the lake, can't wait go give her a good shakedown testing all systems before I start bringing the boost up from WG level of 12-13 lbs.








One of my friends 08 Apex RTX 136" MCX440.

 

[standard]

That should take all of about an hour....
COME ON....
Can't wait any longer to see this rocket ignite..!!!
Count down...3, 2, 1, blastoff
Tom

 

[rxrider]

Tom, thanks, take a look now, I'm done updating