KZEFI 810 Turbo E85 Build

Real solid work your doing there. AND a great job documenting everything along the way. Immensely helpful for the next guy.....! Keep it up bud!

V2 of the crank sensor is done and working well. Although it wasn't really necessary its a good improvement. I sent one of these to Kawasakik1e for his Megasquirt turbo 650.



Changes:
-The shallow missing tooth makes a better signal
-2 missing teeth instead of 1
-Full diameter mount plate
-triple layer trigger wheel for a cleaner laser cut
Start up video

Previous trigger at 1krpm (bridgeport, steady reading):


Current trigger (live engine, kinda erratic):

You can see the higher peak to peak voltage (4V vs 2V mimimum)


I also milled out the 17mm adjuster slot on the zx600 87 swingarm to 20mm for the zr750 setup. Swing arm will need clearancing at minimum travel. Ill have to lathe down the sprocket holder as well. waiting on a 20mm drill bit to trill out the chain adjusters and rear brake brackets.



Other parts are coming in as well.

You've been very busy. Nice work!

So have you! better post up that manifold!

Ok Saablord, here it is.... my first time building a header. Was a bit of figuring it out; never done something like this. Came out pretty o.k.; maybe even a little Sexy!

Congratulations! That is a complex piece to build.
I am wondering if the pipes should be equal length like on a non-turbo header?

Also, when posting pictures, please click the Insert All button so they show up large in the post.

Yes, pipes should be of equal lengths dor.proper tuning; I was working with a tight space limitation.... compressed front end while jigging everything up to make sure front wheel won't touch and Turbo has to be where it is to make sense. My first time, it's a 8/10 for functionality and aesthetic appeal. Can't be any worse than the old ATC log manifold.on the Z1R.....
thanks for the tip on pics. I'll give that a whirl.next time.

TexasKZ wrote: Congratulations! That is a complex piece to build.
I am wondering if the pipes should be equal length like on a non-turbo header?

Also, when posting pictures, please click the Insert All button so they show up large in the post.

I fixed his pictures to make them easier to see

A 4 into 1 ATP spider pipe design with a angled collector would have worked well to balance the flow. ( Hind sight is 20 / 20 ) But applaud the effort
Dave

Thanks for the Picture fix StreetfighterLTD . My next Header I build will be a more balanced effort. This one was figuring out about 8 or 9 new things and just tryin to see if I could get it to merge together. Definitely learned a lot...... lol

Kawasakik1e wrote: Thanks for the Picture fix StreetfighterLTD . My next Header I build will be a more balanced effort. This one was figuring out about 8 or 9 new things and just tryin to see if I could get it to merge together. Definitely learned a lot...... lol

A quality header is a work of art / science /and compromises for fit
Length , size , and amount of restrictive bends all come into play along with how the primary pipes meet and in what order to achieve optimum flow and scavenging.
Then length , size , shape of the collector too. :pinch: :pinch: :pinch:
Turbos are a little more forgiving as long as the exhaust gases spin the turbo enough to get you the boost you are looking for.
Keep up the good work
Dave

Thanks for the Input Dave...! Besides the mentioned parameters I was working inside, I also built this "First" header out of scrap 1.5" tubing from my workplace... so I was also limited by tube size and bend radius.... and availability. The scrap cost.me.less than $5 - works for me. As I said previously, I'm already scheming for the next one to be really nice.
Just want to mention that I also CAD'ed the custom mounting flanges (stock tube is 1.375") to pass through the frame rails AND I CAD'ed the turbo flanges. Cut on laser at my work.... nothing on that header was bought....
So,I'm kinda going on about this but I've had my own buddies ask why didn't I orient it this way or that way.... th is is for anyone thinking of fabing a header. You dont realize what limitations your working with until you get down there and start hanging tube on your bike..... a lot of limitations!

And now I'll turn this thread back to Saablord - he's the guy doing the deep research and smart thinkin'!
Carry on...

equal header lengths are far less important than many people think. The header length mostly effects where peak torque occurs in the RPM range. Sometimes unequal lengths are intentionally created as it produces a broader torque curve. I'm sure that turbo manifold will work just fine. The early turbo setups used a log type manifold, they switched to the spider type because it was thought they would flow better but it created a smaller volume resulting in less turbo lag.