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Project Fuel Injected Turbo FZR250, half

Discussion in 'Your 250cc Projects' started by Mike Green, May 9, 2020.

  1. Mike Green

    Mike Green Well-Known Member Premium Member

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    Intercooler in place. Kevin was kind enough to supply a lump of alloy to make the turbo-intercooler connection. It'll have a rubber hose joint to allow it to move around a bit. I'll probably make a new fuel tank to fit between the seat and the intercooler and there will be ducts to get cooling air to the intercooler in the front. They should fill in the gaps nicely
     

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  2. Mike Green

    Mike Green Well-Known Member Premium Member

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    Very nearly finished with the flanges. Just need to drill the 2 holes in the flange to bolt to the turbo, left one. The other one will probably have a bit more machined off once I figure out how it's going to fit to the bottom of the intercooler core. Inside the turbo flange is 2.5° from about 5mm in through to the start of the other flange. Then the angle changes in 5° steps to 25°(per side) where it will open to the core. I'm not holding them together very well in the photo. When I do I can't see where they join. The OD where the connecting hose will be is 36mmOD
     

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  3. Mike Green

    Mike Green Well-Known Member Premium Member

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    SIGH! It needs to be different. The turbo flange needs to change a bit and I'll make a new bit to weld to it. I also need a 45° elbow that I'll buy from Mikunioz which has a 34mm ID. I'll use the elbow as the way of making the connection when fitting the intercooler
     
  4. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Drats, that machining looked top notch - straight to the pool room?
     
  5. Mike Green

    Mike Green Well-Known Member Premium Member

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    A little bit early for the pool room. Now I've started thinking about the fuel tank. As usual there's far too many options - cut the existing tank and use just the back portion with the outlet on the bottom and the filler, or make a small alloy version, or try a fibreglass copy of the back section and glass in ally bits for the filler and outlets. I really don't want to cut a tank in half but it's looking like the sensible option. Plus, to add excitement to my life, I was thinking of cutting it with a cutoff disc without cleaning the tank. I'll video it for YT of course.
     
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  6. Gen

    Gen Well-Known Member

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    Would the tank fit after the bottom became the sides ?:D (that happened to a local with his cb750 tank, he was warned to strap it, before welding)
     
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  7. Mike Green

    Mike Green Well-Known Member Premium Member

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    I've been working on the duct for cooling air to the intercooler. I've got the outside bits cut and bent and the main bit that forms the bottom of the duct. The last 2 bits are for the front bottom. Hopefully I'll sort that out tomorrow. Cardboard has been a blessing. Much easier to cut, shape, and start again when I screw up.
     

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  8. Mike Green

    Mike Green Well-Known Member Premium Member

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    Progress with duct for cooling air to the intercooler. Luckily the worst of the welding is on the inside. I'm still thinking about how to secure it at the front. There's a few options but I might leave it for a bit.

    A 45° elbow arrived from Mikunioz today so I can get back to making the connection from the turbo to the intercooler. I already have the tapered pipe designed and just need to spin it up using the lathe. As usual the plenum on that side will be mocked up using old cereal boxes.
     

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