Another NyPro Project

[sportsterdanne]

Installed the mesh in the head light openings.




Did some cutting and drilling on the clutch cover and shaved off 170 grams.

 

[sportsterdanne]

Wing nuts in the front.





And a locking pin ? in the rear.







Moved the temp gauge to the riser and installed the pressure gauge in its place.

 

[sportsterdanne]

Some more mesh work.

 

[sportsterdanne]

Time for the oil feed line to the turbo










Removed the welded parts that was unpainted during testing.








Then it was time for some electrical work.

 

[sportsterdanne]

More work with the electrical.





some of the wires that i have removed.



Put it in a plastic bag and 720 grams is the total weight, and there is still some more to remove

 

[sportsterdanne]

Made a bracket for the fuse box and the main fuse.

 

[sportsterdanne]

Sandblasted the steel parts.

primer.

And black paint.

found some water proof connectors


And got my flanges from my friend.

 

[sportsterdanne]

Modified the fuel inlet i cant have it to the rear because of the exhaust and in the front the plenum.


Made a adapter to attach the heads vent to the oiltank vent hose instead of a separate hose all the way to the Catch can.


Modified the filler cap.



Used a straight hose, i will try to find a transparant hose to see the coolant level.

Installed locking pins on the front of clutch cover, also secured them with som wire.

 

[sportsterdanne]

I have decided to make a log style "header" to get the turbo where i want it.
i know its not the ideal style but Ulmers header seems to be working fine and im going to run low boost so i Think it will be just fine.




now its time to mock it up and find the right Place for the turbo flange.

 

[jskattum606]

That Should work just fine. Good work!

 

[sportsterdanne]

That Should work just fine. Good work!

thanks man !


Did some more work on the "header"



it will be something like this.
Im going to see if i can Clock the turbine housing to a better position but the waste gate lever is in a bad spot.

 

[Sheetmetalfab]

Very nice!

Side note. A little scale removal goes a long way when tig welding cast elbows.
Less train tracks ( undercut )

Ya said cast meant forged.

 

[LoudHandle]

Very nice!

Side note. A little scale removal goes a long way when tig welding cast elbows.
Less train tracks ( undercut )

They look like standard forged pipe fittings to me (not cast, few to no pipe fittings are cast these days other than ductile iron or cast iron, neither would be used here and neither would look like those), but agree with proper prep being key to a good weld. Most all qualified weld procedures require a minimum of one inch cleaned on each side of the weld.


Carry on!

 

[sportsterdanne]

Thanks for the heads up. Ill make sure to remove more scale in the future, im a rookie at Tig welding and appreciate all advice !

 

[sportsterdanne]

Drilled the cast Engine plate for the oil return.

And more header work..

 

[sportsterdanne]

I ran out of Argon so i installed the fuel pickups and the fuel sending unit.

 

[sportsterdanne]

Some heat shielding and a aluminum bend from McXpress.

Welded a 90 degree reducer from 2,5" to 2", it will go into the muffler.

this is how the exhaust will be routed, i had to order a flexpipe since i needed a short one.

 

[sportsterdanne]

Did some work on the intake manifold.

 

[sportsterdanne]

My friend helped me mill the flanges and then i sandblasted it.

Some header paint.

I also picked up my sheets of 6082 T6 alu for the tunnel. did some testing on a scrap piece and was able to bend two 45 degree angles pretty close to each other and it looks ok (could not find anyone that could bend it with a radius)

 

[sportsterdanne]

Some parts has arrived.
Flexpipe.

45 degree hose and header wrap.

Modified the right side to get some more clearance, i ordered a Cobra elbow to the intake side on the turbo.

did some more welding on the intake, installed a 25mm tube for the BOV and a 16mm tube for the smaller hose.

Modified the stock heat shield.