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Project ZXR250A - The Wasp.

Discussion in 'Your 250cc Projects' started by Murdo, Aug 14, 2018.

  1. Andych

    Andych Well-Known Member Premium Member

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    What sort of boost pressure do you expect to see @Murdo ?
    I cant see what the top plate of the Plenum thickness is.. but no doubt you have taken it all into account :)

    And I agree that we need that other Button @GreyImport
     
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  2. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    How did you find using those bits compared to normal threading tool? Do you set the drill to low or use a hand turner?
     
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  3. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    Just thought I'd throw this in for anyone who's interested...

    Recent Summernats in Canberra had a Pro Slammer (supercharged doorslammer running alcohol fuel) do HP Dyno runs against a twin turbo big block chev (3,000bhp with 54psi). Interesting results and good writeup. Needless to say, the WASP won't be running 54psi!

    http://www.dragnews.com.au/news-all...o-wins-against-pro-slammer-in-turbo-duel.html
    54psi & 3000bhp.jpg
     
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  4. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Drill on low speed with plenty of lube (WD40 for aluminium). Drill a slightly smaller pilot hole first then use the drill point to drill to final size before the thread cutting engages.
    Andy, the turbo wastegate is set to 15psi, so will see how that goes first before we play with changes. Once we get that sorted then this will come into play to really get the sting working. Top plate is 6mm with 5mm screws.
    https://www.ebay.com/itm/AISIN-AMR5...sh=item3f953eb087:g:9ZcAAOSwovNaM~tT#viTabs_0
     
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  5. Andych

    Andych Well-Known Member Premium Member

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    Holy cow, Turbo’D and Supercharged ......
    If you get that thing sorted you can run tall gearing and keep the RPM at a safe level because you will have power to burn with neither item overly stressed. Can’t say the same for the pistons though



    Sent from my iPhone using Tapatalk Pro
     
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  6. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    When we get into that will need forged pistons and custom made rods. I think the crank would be ok with the short stroke but my main concern would be the head bolts pulling out of the crankcase at high boost and there is not a lot of room for bolts through to the sump. May look at casting an extra thick crankcase with room for through bolts or getting one milled from a solid lump of alloy. Was also thinking that the clutch is a bit weak on ZXR's so may have to go to external dry clutch off something much bigger. If the gear box proves to be too weak then could run a primary chain/belt and use a competition box from something. Anything is possible with enough time and money. :D
     
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  7. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Twin charged , love it
     
  8. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    That is a long way off yet Kiff, and I have never run an engine on fuel only methanol.
     
  9. ShaneP

    ShaneP Well-Known Member

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    Theoretically, the headbolts won't pull and the pistons are rods will be fine. The charge pressure should be the same (increase the combustion chamber volume to offset the boost), so the force is the same. What changes is rate pressure decrease as the volume increases (moves through the stroke). It works on an increase in the accumulation of force rather than increasing the peak. However, older engines or lower performance engines can be boosted without spacing by improving ignition and fueling and cooling. But as someone pointed out to me, there's a lot of overlap on the valves, so you might lose a bit of fuel-air mix out the exhaust. Hopefully it doesn't ignite.
     
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  10. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Have the intake manifolds tacked together and carb in final position.
    MC-14 pistons 003.jpg MC-14 pistons 005.jpg
     
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  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Needs more bling :fuckyou:

    carb.jpg
     
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  12. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    That is not the carb we will be using, just an old dirty one to do the mock up with.
     
  13. Andych

    Andych Well-Known Member Premium Member

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    Turbo Lag.jpg

    There could well be a lot of this.. :)
     
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  14. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Back to this again.
    Have all the bits finished that bolt to the turbine.
    Ride 10-6-2019 001.jpg Ride 10-6-2019 003.jpg
    Waiting on some bits ordered before bolting on to the rebuilt engine. Have all the water lines on and ready for assembly.
     
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  15. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Have made and mounted the oil tank under the engine.
    Used a piece of 6mm alloy for the base and extended rearward to mount the oil pump with a screened pick up and baffle.
    Grafton rally 2019 009.jpg
    Mounts for line fittings and filler cap.
    Grafton rally 2019 011.jpg
    Will be filling with two litres of Jet 11, a full synthetic that runs to 400 deg + in jet engines, so should be a snack in this turbo.
    xxx 002.jpg
    Still more to be done but in position and all fits inside the fairings.
    KE-175 020.jpg
     
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  16. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    These guys do a forged piston in the 50.25mm size with an unmachined head - would you dare take the A model cylinders out 2.25mm over stock - or can you fit C barrels and take them out 1.25mm?

    https://www.daytonaindonesia.com/product-subcategory/piston/forged-piston/102

    I tried contacting them via their website for full specs & drawings but never got a response, if you knew someone going for a holiday in Indonesia I suspect they could just buy some at a shop
     
  17. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Made up a 2mm thick steel plate to cover the riders sensitive parts in the case of a line coming off or turbine explosion.
    VT250 heads 012.jpg
    Have oil cooler for the turbo mounted, still some ducting to be made.
    VT250 heads 014.jpg
     
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  18. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Have made the battery mount and fitted a tempory battery to get the wiring worked out. Made two new cables for starter and earth. Mounted solinoid next to battery to keep wiring short. Made a 1.6mm thick cover over the battery and to act as a air flow smoother behind the rider.
    VT250 011.jpg VT250 013.jpg
    Wiring to oil pump in progress and hoses (after being sent the wrong bits) will be fitted tomorrow.
     
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  19. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Come to a standstill with the wiring as I need a tacho. Anybody have a smashed set of instruments for a ZXR?
    So onto making the oil catch/breather tank. With the turbo on boost there is going to be more blowby past the rings so I made a tank to catch any oil blown out of the crankcase and collect it in an alloy tank mounted so that the oil can drain back to the case and the fumes will be sucked out with the exhaust gases.
    I used some of the 1.6mm sheet I bought last week and my Rosewood mallet on the small sandbag and pounded the snot out of it to get a rough curved shape.
    xxx 003.jpg xxx 005.jpg
    Then with the planishing hammer worked it over a curved dolly held in the vice.
    xxx 007.jpg
    This gave the shape I wanted to be able to fit the tank under the side panel.
    Using some more of the 1.6mm sheet I folded a channel to fit the curved piece and welded together.
    xxx 009.jpg
    With some tabs welded on for mounting bolts and bits of 6mm plate to take the thread for the hose fittings.
    xxx 011.jpg
    It sits under the side cover nice and snug.
    xxx 013.jpg
     
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  20. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    I thought I'd mentioned @GreyImport has a spare ZXR dash.
     

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