Topic: Turbo Charged CB550 Landspeed Attempt

[richmagee7]

Looks like it's really coming along Bombermann.  So, this will be covered in fiberglass?  Or handformed aluminum?  Rich

[BomberMann650]

Looks like it's really coming along Bombermann.  So, this will be covered in fiberglass?  Or handformed aluminum?  Rich

After brazing a bunch of the nose cone wires.  There was an attempt to make paper patterns for kydex thermal molded plastic.
But the paper ordered was no good for such a task.  Inferior to the posterboard that was used to make patterns for the existing seat, tail, and covers.

Then a bed sheet was stretched over the wires.  Which really highlighted how out of place the wire guarding the grips looks.  At this stage, am not ruling out canvas and dope.

Wanted something to cover the wireframe which could work for 3d scanning the bodywork.

In other news, found a 6 foot long level at HF for $15.  Its now in position as a channel from fromt and rear tires.  The wheel track isn't offset by much.  So i spent the afternoon re-aligning the tail fin. This time with more plumbs and center references.  Ended up making a new pair of curved wire to serve as the deck lid.  A shape borrowed from am ultra slippery concept car.

[BomberMann650]

Merry Christmas

Got the pipes back from the ceramic coating shop.
Kinda think i shoulda chose a different color.  The result was kind of a 1930's german army color....
A little more contouring of the welds wouldn't have hurt either.

I should reassemble the engine sooner than later.

[Don R]

 While watching car shows on Motor Trend, I saw a stereo guy making fiberglass speaker surrounds out of Polyester fabric and Polyester resin. He said it made a perfect product; it makes sense that it could be used as a base for overlaying more glass.

[BomberMann650]

While watching car shows on Motor Trend, I saw a stereo guy making fiberglass speaker surrounds out of Polyester fabric and Polyester resin. He said it made a perfect product; it makes sense that it could be used as a base for overlaying more glass.

It is an age old technique.  Glad to see it adapted with modern materials.

In the world of model making theres an aluminum wire mesh method as well.  Which is the direction i went.  Finding a bulk supply of this artistic material wasn't easy.  Will find out after the holiday if this semi rigid formable stuff will get me closer to the finish line.

Had wanted to avoid making a buck/mold due to the extra wasted cost and time.  Yet necessity is pushing things in that direction.  Having a solid base will be more beneficial as the project gets into the 3d scanning and CFD analysis phase.

The day job has left me exhausted over the holiday season.  So progress on the tail section has slowed.  Continuing to examine how the automotive world handles the shear and drag on their back bumpers.  May end up with a rather unique tail piece for this build.
Was able to make a pair of wires to form the seat pan and leg slots.  But haven't brazed those in position yet.  Working at this without my co-conspirator around is kind of a bummer.

[BomberMann650]

The aluminum sculpture mesh came in.  Along with some two sided tape.  Easy enough to work with, and should aid in the quest

Which is getting interrupted by another big move.  Taking it all back to the workshop of yesteryear.

[johno]

r u gunna do ducts to keep that turbo beast cool ?

[BomberMann650]

r u gunna do ducts to keep that turbo beast cool ?

Definitely considering naca ducts. Point some at the cyliders, another for the air inlet.  Maybe some for the tailfin.  If theres any problem with drag back there.

Still have water/methanol injection on the todo list.  Did get a solid lead on compact pumps for the wmi rig.  But first the charging system needs uprated.  Electrex is on holiday, and the credit card could use a vacation as well 😅
Once everything is back in a real workshop.  Will turn focus onto the aluminum fab jobs.

For the interim, engine reassembly has begun.  The head has been uhhh... Serviced. 
The big ports have become a balancing act as oem gaskets no longer work.  Making copper gaskets for the intake was fun.  Trying to source a suitable gasket for the exhaust is a nuisance as well.  Needs to be thin and squishy to allow the v-band clamp to mate at the secondary pipe.  At least the Permatex worked last time.
The dynoman guides are in and the seats are cut, along with a new-new set of common motor dotcoms valves.  The service shop even checked the overlap clearance with the cb650 .308 lift cam.  For the record, there is 50 thou.  So the kpmi +1 valves are an option for people wanting to go that route.  Personally didn't buy into those parts, because budget and boost.

A set of 4into1 dotcoms ductile piston rings arrived today.  So the cylinders are off for a cleanup and new ring fitment.  The ring gap factor from initial assembly was likely overkill.  So that will be tamed down.  The piston skirts left their mark on the cylinder walls. But nothing catastrophic.  The big ends of the connecting rods are still shiny so it seems i got the bearing fitment right.

Haven't determined which big bore is the way to go.  600+ cc with a flat top piston would help.  Would feel better going there with a set of heavy duty sleeves.  There aren't many 60mm options that can be called budget friendly.  To go seriously over square like 636 would require additional machinng.  Perhaps later in the campaign.  Once the stock bore is fully "stuffed" and the bike goes faster than rich's bike. 

[BomberMann650]

Win some lose some.  The 4 into 1 ring set allowed me to set the end gaps at a factor of bore x . 008" - hastings turbo spec.  But just barely.

Real problem is the clearance in the groove of the imd374 pistons dont leave much room.  Unable to pass a .0015" feeler in between the ring and its landing.  Mic'd the 4 into 1 rings against the imd ring and theres a small 1/2thou difference.  Which proved consistent (.0003" variance) across the set of 4.

Could probably clean the ring landings with aggression and send it.  This is the result of being opposed to international ordering new rings from imd and justifying the 4 into 1 ductile iron set as "good for turbo".

Edit; measured twice, quit freaking out over details

[BomberMann650]

A frenzy of assembly later and the changes keep on changing.

With a new, single-layer base gasket, the re-rung pistons bring deck clearance down to .012 thou.
Crunching the numbers on a .040" gasket with 13.1cc chamber volume nets 9.2:1 CR.

APE studs torque spec at 22ft-lbs.  Unfortunately the "lucky stud" that was in some repaired threads - may have run out of luck. Something that will have to be dealt with after the move.  Seems the 65mm bolt at the front and center could use a helicoil too.

Annealed the copper gaskets and learned the turbo flange would require an o-ring to seal.  Found a scrap of wire and will let the kopper-kote handle the rest.
In the process of cleaning the exhaust system, found the gasket for the waste gate had burned out.  Took the time to make a copper gasket for the gate, and lapped the WG fire ring a little.

Decided to experiment some with the header seals i had acquired from amazon.  Peeling the stainless wire from the copper jacket and flattening it down with some permatex inside.  Should work, and the donor part is easy to acquire.

Put the carb adapter on the turbo and sealed the compressor volute to the bearing cartridge.  Bolted to the head with the gasket and kopperkote.  Will have to check for leaks later.  May not hurt to uprate the studs and nuts for the intake too.

The headers look nice, back on the bike.  All smooth and coated.  And very .... Grey