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KZEFI 810 Turbo E85 Build
- Saablord
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13 Jan 2021 14:52 - 13 Jan 2021 14:58 #841676
by Saablord
Replied by Saablord on topic KZEFI 810 Turbo E85 Build
Here's another update :ohmy: I moved the missing 12/21/20 post into my post earlier today and then moved that newer stuff here so its in chronological order 
I sorted out the AN lines and fittings for the oil feed. It starts with a M18x1.5 to 4AN adapter i found on ebay. There is a matching M10x1 to 4AN adapter in the turbo. Between are a couple AN lines and a 44u turbosmart filter. I may rework this again as i dont like how far the AN elbow sticks out under the cover.... It'd be the first thing to hit if the bike ever falls.
The main delay was the welder. I couldn't get my DC tig to do AL with any of the workarounds, so I splurged and bought a MTS 225 AC/DC tig/mig from Everlast. Heat control and bead consistency is even harder on AL, so by beads aren't the prettiest, but its good enough for now... Need to test out that pedal control.
I welded up the oil cooler. If you remember... there were slots in the mount plates to weld the tubes behind them. It got messy due to the difference in the parts, so i ground it flush to hide my sins. :laugh:
and the mount for the scavenge pump. Still need to finish the routing for these lines.
and the battery box
and the intake piping
The next thing is the wiring. I started by installing a little license plate light.
In the bottom right photo below you can see a tab welded onto the frame. Ill use plastic clips to hold the fender material to the frame through these mounts.
I sorted out the AN lines and fittings for the oil feed. It starts with a M18x1.5 to 4AN adapter i found on ebay. There is a matching M10x1 to 4AN adapter in the turbo. Between are a couple AN lines and a 44u turbosmart filter. I may rework this again as i dont like how far the AN elbow sticks out under the cover.... It'd be the first thing to hit if the bike ever falls.
The main delay was the welder. I couldn't get my DC tig to do AL with any of the workarounds, so I splurged and bought a MTS 225 AC/DC tig/mig from Everlast. Heat control and bead consistency is even harder on AL, so by beads aren't the prettiest, but its good enough for now... Need to test out that pedal control.
I welded up the oil cooler. If you remember... there were slots in the mount plates to weld the tubes behind them. It got messy due to the difference in the parts, so i ground it flush to hide my sins. :laugh:
and the mount for the scavenge pump. Still need to finish the routing for these lines.
and the battery box
and the intake piping
The next thing is the wiring. I started by installing a little license plate light.
In the bottom right photo below you can see a tab welded onto the frame. Ill use plastic clips to hold the fender material to the frame through these mounts.
Last edit: 13 Jan 2021 14:58 by Saablord.
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- Saablord
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24 Jan 2021 20:41 #842337
by Saablord
Replied by Saablord on topic KZEFI 810 Turbo E85 Build
I finished up the rear fender. It looks pretty good from the outside
I got distracted rebuilding the vacuum chamber with my new welder. This has .06" restrictor holes compared to the .125" in the previous version and it also has a larger volume so it'll average out the map readings better. I can machine smaller restrictiors if i need to.
The turbo scavenge pump has been plumbed in... it dumps oil back into the breather cap. I've also connected the scavenge tank to this breather plate (so the scavenge pump doesnt pull vacuum through the turbo). The last line relieves crankcase pressure to the turbo inlet. I'll add a copper sponge in here as well to help condense the vapors. Technically there should be a line to the intake tract with a check valve to assist with vapor extraction off boost, but that's a bit messy with ITBs.
Made some prototype routing clamps for all the lines.
I played with one more turbo oil feed setup. Its a m18x1.5 to m10x1.0 bushing with a M10 to 4an banjo. This is lower profile but it would still get hit if the bike falls over..... So i'm keeping the old setup.
The turbo had to be pulled off to modify the internal wastegate. It opened at 20/25psi stock, so this spring lowers it down to 7psi.
....As it sits right now. I need to plumb and wire the new fuel pump , then do a test start.
I got distracted rebuilding the vacuum chamber with my new welder. This has .06" restrictor holes compared to the .125" in the previous version and it also has a larger volume so it'll average out the map readings better. I can machine smaller restrictiors if i need to.
The turbo scavenge pump has been plumbed in... it dumps oil back into the breather cap. I've also connected the scavenge tank to this breather plate (so the scavenge pump doesnt pull vacuum through the turbo). The last line relieves crankcase pressure to the turbo inlet. I'll add a copper sponge in here as well to help condense the vapors. Technically there should be a line to the intake tract with a check valve to assist with vapor extraction off boost, but that's a bit messy with ITBs.
Made some prototype routing clamps for all the lines.
I played with one more turbo oil feed setup. Its a m18x1.5 to m10x1.0 bushing with a M10 to 4an banjo. This is lower profile but it would still get hit if the bike falls over..... So i'm keeping the old setup.
The turbo had to be pulled off to modify the internal wastegate. It opened at 20/25psi stock, so this spring lowers it down to 7psi.
....As it sits right now. I need to plumb and wire the new fuel pump , then do a test start.
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- Saablord
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09 Apr 2021 06:25 - 09 Apr 2021 06:26 #846426
by Saablord
Replied by Saablord on topic KZEFI 810 Turbo E85 Build
I'm still alive over here
K1e lasered the rest of the flanges for me so i can finish the manifold. I also bought some 2" mandrel bends and perforated tubing so i can build a glasspack that sits under the oil pan.
I've been finishing the dash area so i can start the wiring. I designed a three gauge waterproof enclosure for my AFR, boost and oil pressure gauges. It also mounts the ignition switch and the koso speedo. I also bought a Maier small sport fairing to finish off the aesthetics.
K1e lasered the rest of the flanges for me so i can finish the manifold. I also bought some 2" mandrel bends and perforated tubing so i can build a glasspack that sits under the oil pan.
I've been finishing the dash area so i can start the wiring. I designed a three gauge waterproof enclosure for my AFR, boost and oil pressure gauges. It also mounts the ignition switch and the koso speedo. I also bought a Maier small sport fairing to finish off the aesthetics.
Last edit: 09 Apr 2021 06:26 by Saablord.
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- Bent Trigger
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- Kawasakik1e
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25 Apr 2021 21:34 - 25 Apr 2021 22:09 #847469
by Saablord
Replied by Saablord on topic KZEFI 810 Turbo E85 Build
Thanks k1e and Chris. email notifications are going to spam again
Here's a better picture of the dash:
I've made more progress since the last update... The 810 motor still needs some work but I wanted to have adjustable cam gears before I dig into that. Ill be using a 750 intake cam with a 650 exhaust cam.
Fixed the kickstand so it doesnt hit the rear set during shifting:
Welded the flanges k1e sent me (and used a jig this time so the SS cant warp... not playing games
). I should've used more shielding gas on these so no pretty colors
Made some proper brackets for the fairing:
The oil cooling system is now plumbed up. This pan doesnt have the diverter plug like the 810 motor, but it doesn't matter for testing.
Next up is making an exhaust that'll look something like this. 2" from the turbo, then it splits to dual 1.5" side exits behind the foot pegs. This sits under the oil pan.
I also need to fix the dent in the gas tank so I can coat it for E85. Then I'll get back to wiring, I swear
... well i have done a bit of wiring, but not enought! I also bought a lift in the past few weeks (can bee seen in the last post
).... It's so much easier to work on!
Here's a better picture of the dash:
I've made more progress since the last update... The 810 motor still needs some work but I wanted to have adjustable cam gears before I dig into that. Ill be using a 750 intake cam with a 650 exhaust cam.
Fixed the kickstand so it doesnt hit the rear set during shifting:
Welded the flanges k1e sent me (and used a jig this time so the SS cant warp... not playing games
Made some proper brackets for the fairing:
The oil cooling system is now plumbed up. This pan doesnt have the diverter plug like the 810 motor, but it doesn't matter for testing.
Next up is making an exhaust that'll look something like this. 2" from the turbo, then it splits to dual 1.5" side exits behind the foot pegs. This sits under the oil pan.
I also need to fix the dent in the gas tank so I can coat it for E85. Then I'll get back to wiring, I swear
Last edit: 25 Apr 2021 22:09 by Saablord.
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- 531blackbanshee
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27 Apr 2021 09:21 - 27 Apr 2021 09:23 #847536
by Saablord
Replied by Saablord on topic KZEFI 810 Turbo E85 Build
Here are a couple more pictures....
The bracket and nut thing for the oil thermostat mount
Making the shell for the exhaust... Roll former and a janky press brake setup
Lookin good
The bracket and nut thing for the oil thermostat mount
Making the shell for the exhaust... Roll former and a janky press brake setup
Lookin good
Last edit: 27 Apr 2021 09:23 by Saablord.
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- Bent Trigger
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03 May 2021 08:57 - 03 May 2021 09:02 #847920
by Saablord
Replied by Saablord on topic KZEFI 810 Turbo E85 Build
Finished up the glasspack this week. It went pretty well but i shouldve been more careful welding the shell seam. Still hate how much SS warps
Packed with fiberglass and ready for jigging under the motor. All the ugly stuff is hidden on the top of the muffler and everything else can be sanded smooth and polished in the end.
Made a die to form 1.5" tubing to fit the vband. I plan on using aluminum for the side exits as its lighter and i dont want to mount those to the frame.
Side view. I'll add two support rods with heim joints from the frame down to the rear of the muffler.
Front view.
Pulled the dents out of the tank. Will probably sand blast this, tig a small hole or two where the seat rubbed and then prime and bondo
Hope to get the tank and exhaust finished this week
Packed with fiberglass and ready for jigging under the motor. All the ugly stuff is hidden on the top of the muffler and everything else can be sanded smooth and polished in the end.
Made a die to form 1.5" tubing to fit the vband. I plan on using aluminum for the side exits as its lighter and i dont want to mount those to the frame.
Side view. I'll add two support rods with heim joints from the frame down to the rear of the muffler.
Front view.
Pulled the dents out of the tank. Will probably sand blast this, tig a small hole or two where the seat rubbed and then prime and bondo
Hope to get the tank and exhaust finished this week
Last edit: 03 May 2021 09:02 by Saablord.
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- rstnick
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04 May 2021 08:35 #847987
by rstnick
Rob
CANADA
Need a key for your Kawasaki? PM me
1978 KZ650 C2, 130K kms, Delkevic ex, EI, CVK32, PMC easy clutch, ATK fork brace, steering damper, braced swingarm, 18" Z1R front wheel.
2000 ZRX1100
2011 Ninja 250R
2005 z750s
Replied by rstnick on topic KZEFI 810 Turbo E85 Build
Great work you've been doing.
Looking forward to the rest.
Looking forward to the rest.
Rob
CANADA
Need a key for your Kawasaki? PM me
1978 KZ650 C2, 130K kms, Delkevic ex, EI, CVK32, PMC easy clutch, ATK fork brace, steering damper, braced swingarm, 18" Z1R front wheel.
2000 ZRX1100
2011 Ninja 250R
2005 z750s
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- Saablord
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10 May 2021 09:42 - 10 May 2021 09:54 #848303
by Saablord
Replied by Saablord on topic KZEFI 810 Turbo E85 Build
It was rainy this weekend so I finished the exhaust and started the remaining motor upgrades.
Welded the down pipe from the turbo to the glasspack.
Welded the aluminum dual exit section
Underside view
The rear glasspack mounts.
The motor in pieces
I got the head back on with the new .08 base gasket. Still need to dial in the cams and install the clutch and oil system parts
I should be able to finish up the motor stuff in the next day or two and then get on to the tank.
Welded the down pipe from the turbo to the glasspack.
Welded the aluminum dual exit section
Underside view
The rear glasspack mounts.
The motor in pieces
I should be able to finish up the motor stuff in the next day or two and then get on to the tank.
Last edit: 10 May 2021 09:54 by Saablord.
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