The first mod working towards the turbo setup is the Wideband gauge and switches. I welded up and painted a stainless bracket to suit and here's the result! The hardest part was managing a functional spot to keep it all without hindering speedo view and making the switches easily accessible while riding. the switches are for: Manual radiator fan over ride, ECU map switching (spicey tune) & switching the exhaust cut out.. so the turbo will be routed back up into the Yoshimura carbon mufflers but with an electric exhaust cut out under the belly.

Proof of concept and practical location:

Completed installation:

The old PCV & autotune setup which I'm selling on along with the OEM ECU as I'll be running the haltech elite 1500 (to maintain the DBW setup these motors utilize - a bit part of boost management!)

 

Turbo mock up and placement!

Bloody hard to find a spot for a turbo on this bike given the radiator hose setup and oem water/oil cooler. I'm thinking ill move to an external air/oil cooler setup to save space and to lessen the loading on the all ready taxed coolant system. Moving to an external cooler should allow more room for the external wastegate to tuck up under the bike as ill be welding it direct to the turbo exhaust housing for the best exhaust priority and boost management.

So this is the turbo I have laying about, a Borg warner K16 T2 flange turbo. Roughly a T28 sized turbo. You can see I'm also playing with lowering the bike.. probably 25-30mm to keep the ability to still take some turns..

The ideal location.. almost.. I think ill try to move it forwards and lower to keep the weight in a position to help keep the front wheel down.

Hoping to minimize cutting up the fairings too much and i think I should be safe.

Welded up a fixture for better visual reference and planning.

It'll be tight to get the exhaust run back to the Yoshimura setup and fit an electric exhaust cut out.. but we'll see how we go

I'm hoping to manage to squeeze a 4-1 merge collector in here too.. sure a log style manifold would suit but where's the challenge!?

It was at this point I really noticed that its quite a large turbo 🤣

 

3D printed some flanges and 1 1/4" spec Schedule 10 stainless steam pipe elbows to mock up the manifold. Tight but manageable.. Just winging it with the radiator clearances as its something I can deal with later. The radiator has a bit of room for swinging forwards on it two top mounts so should be fine.

Dummy fitting the 44mm external wastegate.. She's big!

You can see the oil cooler and coolant lines take up a lot of valuable real-estate, however there's plenty of room to move the turbo forwards of the engine unlike my Hyosung GT650R LAMS bike that I turbo'd, the V-Twin left minimal space between the turbo, front wheel and engine!

I bought a Creality Ender 7printer and this is actually the quality straight out of the box with no setup or calibration. Pretty impressed!

Super tight fit, think ill make the merge collector a little longer to place the turbo lower still..

44mm External wastegate tacked on for fitment testing, all though a big gate, there's just enough room and perfect placement for a tear drop dump pipe exiting down on the left hand side within the bounds of the lower cowl.
This should put on a wild show banging between gears with the quick shifter 😁

If only it were as easy to just glue manifolds together! So here im testing out the merge collector jig I made for the band saw.. and it works perfectly

 

Very impressive fabrication skills my man!

 

Sick build can't wait to see it evolve!

 

What boost level are you planning to run? Did you lower the CR when you did the head gasket?

 

Hey mate! So boost will be a peak 5psi and controlled via a 3 port MAC and PWM signal from the Haltech elite. Essentially boost by speed to begin with.

The initial setup is stock block, actually slightly high comp that stock as it runs a Competition headgasket. This will be fine and manage 200whp+ on 98 with fuel and ignition corrections & running a knock sensor with the R1. The other consideration is ill be on flex fuel and run E85 along with the water to air intercooler to keep IAT in a safe range

Future plans are rods, pistons, ARP studs and cryo treating the gearbox gearsets to push the WHP up

 

Finding some time to chuck this thick walled stainless steampipe manifold together! I'm a novice welder and learning the process of back purging stainless welds while also learning the sequence in which to weld and assemble a turbo manifold in a very tight space constraint of the R1 😅

 

Looks very good for your first time welding stainless. Glad you are making progress with the bike. There is no better satisfaction than going from idea to finished project......

 

An H2 Killer ? Unbelievable,,,

 

Update time!

Just ventured out on my own, full time working in my own shop so been a bit busy!

Long story short, got the manifold welded up and mocked the whole setup in the bike which is a step in the right direction, however, I'm not 100% happy with turbo placement.

1. with the additional flange welded to the turbo housing to rotate the bolt pattern to suit (the borg-warner i got has the flange 90 deg off the other direction) has the turbo sat 12mm lower.
2. the small t25/28 flange on the collector.. the center hole being smaller than i had envisaged means the flange sits quite far down the taper of the collector.. again sitting everything a touch lower than is ideal.
3. the combined 1. & 2. issues has the turbo too low to run a decent oil collection sump under the turbo for the scavenge pump setup.

I have decided on moving to a PSR2871 Dual ball bearing, Dual V-band, S/S exhaust housing with T51R mod. Firstly I can cut the T25/28 flange off and weld the 2.5" v-band much higher up the merge collector, on a 3-4 degree angle to move the turbo up and a touch in by doing this. Also, It will rectify the double flange issue on the borgwarner saving yet more ground clearance. This turbo also allows less back pressure restriction too, the only real co in the extra welding and needing to run the external wastegate clocked slightly different.

After that, there is suitable room for the water to air intercooler radiator and the external oil cooler too. And lets face it.. turbos just look wild on the R1!!


Mock up on the stand, the position doesn't seem too bad...

But when in the bike its a bit low for street use.. sure for playing silly buggers in a straight line it will likely be fine but i want to be able to take it out to the odd show and coffee shop too..

So if you can immagine the PSR2871R turbo being a better fit, all though larger turbo, coming in and sitting about an 2-3cm closer to the block and up a good 6cm+ with the wastegate re-postioned to still fit under the fairings I'll be much happier!

Also have had the new stand alone rock up! The best part of the EMU black ecu is that i can retain the electronic throttle bodies and use them for wheelie/launch control in the future!

 

CRAZY! Wish I had the fab skills for that project. In for the updates.

 

DAMN! Ok so its been a hot minute since updating this we project.. Transferring over photos from my phone and about to create some more YT videos on this girl so keep your eyes peel over the next couple of days.. shes nearly complete