Is it only me? I look at the first photo and all I can think is "watch me pull a rabbit out of my CNC machine".
Nice work toro.
Nice work toro.
My supercharged K8 project...
The bike pictured above is my bone stock K8. A friend gave me a fantastic deal on this bike last year, and it has just under 2000 miles on the clock. I love this bike for the same reasons everyone does -- incredibly smooth, extremely capable and controllable, great power, and fantastic ergonomics for a supersport machine. The local Dynojet 250i says it puts down 152whp (SAE corrected), which is actually more power than a full-exhaust, PCIII-tuned '04 ZX-10R produced on the same dyno.
Now, normally the next step would be to add an exhaust, change the gearing around, or add some braided lines, and while I'll eventually get to those mods, I have something different in mind right now...
It's a Rotrex C15-60 supercharger, right off the plane from Denmark. This little unit can support over 230whp, and that's the number I'll be shooting for with my little project here. Also, the impeller wheel used to be cast, but these new wheels are apparently machined out of billet.
Before you ask, yes, I am a power junkie. There's just no going back once you've ridden a boosted literbike...
You can see how small it actually is compared to the bike. Somehow, some way, it will fit in there...
After staring at this sight for a couple of days, I realized the only place to put this thing is in-between the engine and the radiator, just below the frame. I'd love to stick it up higher, but the frame would get in the way of the belt (which is a dealbreaker) and the radiator fan would also have to be relocated. Placing it lower eliminates these problems, but makes it much harder to hide the drive behind the fairings and also places the inlet of the Rotrex very close to the header. I also do not want cornering clearance to be compromised at all, so it will be in as far (and up as high) as possible.
If anyone is wondering how I plan on driving this thing, take a look at the picture above. The M10 bolt currently fastened into the end of the crank will be removed and a machined adapter will take its place (this adapter has to locate perfectly off the crankshaft for this to work). A pulley will sit on top of this adapter and then drive the supercharger via an 8mm synchronous belt. The supercharger bracket will either take the place of the stock cast cover or locate off of it -- I'm not exactly sure yet which way to go.
There's a lot of work left to be done, but I'm looking forward to it. I plan on tuning the ECU directly and, of course, it will run on pump gas. In the meantime, wish me luck, and stay tuned...
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Thanks for the compliments, guys. I've got a lot more coming, too (wait until you see my little exhaust project).
Anyway, some more updates. I rocked out the PAIR block-off plates:
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So much cleaner. These were the easiest parts to create yet, just needed a fixture, blank prep, and final cutout stage. I plan on having these anodized as well.
Next up is the throttle body runner plate...
Anyway, some more updates. I rocked out the PAIR block-off plates:
So much cleaner. These were the easiest parts to create yet, just needed a fixture, blank prep, and final cutout stage. I plan on having these anodized as well.
Next up is the throttle body runner plate...
2
Here we go again...
In order to maximize the efficiency of the intake, a custom throttle body adapter plate will be made to exactly match the runner geometry. I start with a blank, then cut it to length and face both sides so it ends up at the final thickness:
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After lots of chips and with the help of some special endmills, we end up with tapered runners and fully radiused inlets:
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Back when I made the Kawi parts, I designed the TB adapter fixture to accept any adapter plates I could possibly come up with, regardless of bore size & spacing. Thus, after clamping the fixture and mounting the part, I'm able to machine the bottom side. BTW, I actually had a custom endmill made to put the little ring around the runners (which gives the silicone connectors something to bite onto).
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I'd say it's a pretty good match. The bores are much bigger than the 10R.
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One more part done. I'm quickly running out of stuff to machine...
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In order to maximize the efficiency of the intake, a custom throttle body adapter plate will be made to exactly match the runner geometry. I start with a blank, then cut it to length and face both sides so it ends up at the final thickness:
After lots of chips and with the help of some special endmills, we end up with tapered runners and fully radiused inlets:
Back when I made the Kawi parts, I designed the TB adapter fixture to accept any adapter plates I could possibly come up with, regardless of bore size & spacing. Thus, after clamping the fixture and mounting the part, I'm able to machine the bottom side. BTW, I actually had a custom endmill made to put the little ring around the runners (which gives the silicone connectors something to bite onto).
I'd say it's a pretty good match. The bores are much bigger than the 10R.
One more part done. I'm quickly running out of stuff to machine...
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