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Ok some of you might had seen my previous thread of the turbo katana build, well to recap that, i sold all my turbo parts to make up for the thousand i was short on buying my buell and buying a house, so the project got put on hold. Almost sold the kat in the summer to a friend, but couldnt bear to get rid of it after riding it only a total of 50miles and a new paint job.....soooooo the B!tch is getting boosted 100% this time.
so being this time im starting from bare scratch and not a bench full of parts. Im gonna focus on this build as a low budget build that anyone one on here can do with basic mechanical knowlege and a few relavant must have tools. (Mig welder-not that fluxcore crap..you need to beable to seal weld, Drill press, counter sinks, lots of drill bits, angle grinder, chop saw)
Also beable to have access to a metal supplier (your local hardware store will have it but its expensive...were keeping the price down here remember...and able to get npt and/or -AN fittings. know how to weld Aluminum is a plus or knowing someone that does.
1. Modifying the petcock.
Get rid of it. it will restrict too much fuel even in prime. This is what i came up with. Being im running the fuel system as a return type. The benefit is a smooth fuel flow without just relying on the spring of your regulator, trust me its more dicking around, but will save you a headache when you gotta tune your carbs.
I cut a piece of 1"x1" 6061 aluminum square stock and drilled out my bolt pattern, then on center drilled two more holes in the center of the bolt pattern, one of which is only .500" down, which is the return line. The other one is drilled straight through as this is gonna be your feed to the fuel pump. On the side of the piece i drilled .500" on center to where the return was just drilled, making an "L" cavity in the flange.
The return is tapped using a 1/8 npt. as is the feed, the bolt holes are counter sunk to accept a M6 machining screw. The inner hole that meets the gasket side of the tank is stepped up to alow more flow
The return line need to actually go into the tank and sit at the highest point. If your gonna do what im doing then a portion of the tank needs to be cut out to plumb in the hard lines
And when your done it will look like this mounted (this was taken for a referance, as i still need to cut the tank to feed the cooper tube through at a later time)
Oil Feed for turbo:
I took the feed off of the feed lines that go to the valve cover (either side works) you can buy this from Mr. Turbo but why not save $80 and make the adapter yourself, remember the left over 1x1" alum.??? Copy your pattern just like the petcock,
now the top of the flange i made a "T" cavity. counter sunk all holes on face side and lightly counter deburred the back.
Tap the top for an 1/8"NPT
add an NPT to -4AN fitting and mount up
and then connect the other -4AN line to this
obviously the turbo isnt mounted anywhere yet (btw: its a KKK KP31)
-
so being this time im starting from bare scratch and not a bench full of parts. Im gonna focus on this build as a low budget build that anyone one on here can do with basic mechanical knowlege and a few relavant must have tools. (Mig welder-not that fluxcore crap..you need to beable to seal weld, Drill press, counter sinks, lots of drill bits, angle grinder, chop saw)
Also beable to have access to a metal supplier (your local hardware store will have it but its expensive...were keeping the price down here remember...and able to get npt and/or -AN fittings. know how to weld Aluminum is a plus or knowing someone that does.
1. Modifying the petcock.
Get rid of it. it will restrict too much fuel even in prime. This is what i came up with. Being im running the fuel system as a return type. The benefit is a smooth fuel flow without just relying on the spring of your regulator, trust me its more dicking around, but will save you a headache when you gotta tune your carbs.
I cut a piece of 1"x1" 6061 aluminum square stock and drilled out my bolt pattern, then on center drilled two more holes in the center of the bolt pattern, one of which is only .500" down, which is the return line. The other one is drilled straight through as this is gonna be your feed to the fuel pump. On the side of the piece i drilled .500" on center to where the return was just drilled, making an "L" cavity in the flange.
The return is tapped using a 1/8 npt. as is the feed, the bolt holes are counter sunk to accept a M6 machining screw. The inner hole that meets the gasket side of the tank is stepped up to alow more flow
The return line need to actually go into the tank and sit at the highest point. If your gonna do what im doing then a portion of the tank needs to be cut out to plumb in the hard lines
And when your done it will look like this mounted (this was taken for a referance, as i still need to cut the tank to feed the cooper tube through at a later time)
Oil Feed for turbo:
I took the feed off of the feed lines that go to the valve cover (either side works) you can buy this from Mr. Turbo but why not save $80 and make the adapter yourself, remember the left over 1x1" alum.??? Copy your pattern just like the petcock,
now the top of the flange i made a "T" cavity. counter sunk all holes on face side and lightly counter deburred the back.
Tap the top for an 1/8"NPT
add an NPT to -4AN fitting and mount up
and then connect the other -4AN line to this
obviously the turbo isnt mounted anywhere yet (btw: its a KKK KP31)
-
'03 600 Kat
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