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Project Fuel injected ZXR project (Backordered tools make me sad)

Discussion in 'Your 250cc Projects' started by DamnitLaverty, Nov 19, 2020.

  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  2. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Speaking of welding, here is a great vid of how the poms do the beautiful bronze welding of frames like you see on Harris, Arial Atom and since forever with all manner of specialist frame builders. The point of all this, that none of the people making comments on this video seem to get, is that it is not hot enough to get distortion, which is pretty obvious I would have thought and very important for motorcycle frames. Speaking of which, Ducati have been moaning forever about how they can't get consistent handling out of steel frames. Duh, who in their right mind would mig chrome-moly? The stuff was designed for making aeroplane frames and to be to be gas welded.
     
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  3. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    He's a great educator - I believe I learnt my weave, which he does, from him on the very early days - beats blowing holes in the cut edges
    Next is Mr Tig for all things Tig
     
  4. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    45E3C3C0-DD0F-4F40-9EDA-A1A40E140B4B.jpeg 3560F7D5-7206-4919-AA54-68C136849C28.jpeg So went to bug a friend today, he has the proper drill for fuel rails (I did my bungs with a 14mm drill on tube) and a lathe. We (he, really) made dummy injectors for welding the manifold, and drilled the rail. I’ll still need to shorten it at some point- it’s 50mm too long right now.

    Injectors are Monster 696 units (330cc) so they’re a bit big, but they were cheap.
     
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  5. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Here is another welding hint for you. When you want to weld something set up some scrap of the same thickness and position and practice. Also use a good mask that allows you to see your puddle clearly. Even if settings are not perfect you can just work your puddle to compensate. Test the welds you have done by pressurizing them at 5psi and brush on soapy water to check for leaks. It will bubble if there are any.
     
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  6. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Because I don’t have end tanks on yet to pressurize, I’ve been running a flashlight over my welds just to look for light on the far side. Will pressurize once it’s complete :)

    I have a really cheap mask, but I’ve been borrowing an auto-darkening Speedglass to make it easier. Problem i face, even with a good helmet is that I’m half-blind, literally. I have SO much trouble seeing the puddle before burnthru. I’m getting real good at patching holes tho!
     
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  7. DannoXYZ

    DannoXYZ Well-Known Member

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    You're doing really good pro job on this! :thumb_ups:
    Many aftermarket EFI kits uses RUBBER hoses to supply petrol to injectors. :mad:

    Have you seen Greg737's EFI conversion on Ninja 250 and Bandit 400?
     
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  8. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    I haven’t. I’ll Google later, but it’s not limited to just aftermarket. The Ducati I took the injectors from does too! I was shocked! AF6AA3ED-F12E-4BE8-9F5A-C5AD51060F57.jpeg
     
  9. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Weaving will definitely help you there - think of it like doodling on a piece of paper, or for me it was like practicing o o in running writing in little school - once you get that working and it spreads the heat it gets much easier
     
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  10. DannoXYZ

    DannoXYZ Well-Known Member

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  11. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Nice! I’m out in the garage today, welding up exhaust on the turbo shitbox car- once I get back indoors I’ll start reading!

    definitely getting experience building fixtures for parts and welding dissimilar metal today. stainless to mild, to chinesium, to thick ass hanger round stock. Giving the voltage and feed knobs a workout.

    luckily, I have a motorcycle dyno within 15 minutes - I do NOT wanna build a dyno. That’d annoy the neighbors
     
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  12. DannoXYZ

    DannoXYZ Well-Known Member

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  13. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    2CFA070A-2647-4B03-B188-673DA458961B.jpeg “I’ll make an intake manifold” I said. “It’s just a piece of tube, it’ll be quick!” I said.

    It was not quick. I’m too lazy to video right now, so this is where I am so far.

    I spend as much time waiting for this thing to cool as I do actually working. Kinda frustrating.
     
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  14. jmw76

    jmw76 Well-Known Member Premium Member

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    I understand where you are at. All those joints on complex curves and tight spacing makes it difficult to manipulate the torch and get a good clean run. I am certainly no better with my welding and I take forever trying weld up simple tube based parts.
    Blow one hole and you spend forever patching it up.
    Have fun.
    Peter.
     
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  15. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Oh man you dialed it... I’m learning as I go- and everything is such small radii... I cut that TB area way too big and got to practice patch paneling. One side was about 10mm gap- I made a patch. The other side was about an 8mm gap- I bridged 8mmx60mm of open cavity. Learning experience.
     
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  16. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Shock’s in. Still gotta clean and rebearing the swing arm, but it fits.

    triple adjustable winning. 2FB647FA-AD57-4F16-B9CA-80E4AE7500C4.jpeg
     
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  17. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    2BB36E25-EDAE-4683-BBE0-49458EB231A3.jpeg C7C11E1D-3FF3-4147-BD0B-07AE54640466.jpeg Excepting the power wire to the fuel pump, wiring is complete- was waiting on new wideband, the one I planned to use didn’t have an output- back on the shelf it goes!

    Next up is fuel system. There’s no room for anything in here. This is gonna be a challenge fitting a pre filter, pump and return/regulator with a swirl pot lol tiny bike.

    Filming videos takes time I could be working. Bleh.
     
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  18. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Did a video.

    Then went to order the tool I needed, and found out the 37* dies are on backorder for ~3 weeks. Looks like ima find some other ways to keep myself busy for a few days. I can at least start mocking up lines, even if I can't make them wholly yet.

     
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  19. crshbndct

    crshbndct Active Member Premium Member

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    When you say the shock is from an R6R, do you just mean R6? or is the R6R some special model of R6? Or does it refer to a model year? Like ZXR250 A, C etc?

    From what I can tell R6R refers to a 2006-2008 R6, but I just want to confirm before I spend $600 on a shock.
     
  20. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    So, starting in 2006, you could buy the R6, new bike, new tech, new look. On the market at the same time, was the R6S, which was the old generation R6, dressed up to look like the new one.

    How the R6 got the R moniker, I have no idea. This is a new gen R6 (2006+) shock.

    Since I have it out to put the swingarm back in, I grabbed a side by side pic for you. I measured it at 290mm eyelet to eyelet vs 281 for the stock shock. A38693A1-023D-4EC4-91B1-34F34BBBE02D.jpeg
     
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