Another Budget zx12r turbo build - Kawasaki Forum :: KawasakiWorld.com
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post #1 of 46 Old 06-02-2016, 04:38 PM Thread Starter
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Another Budget zx12r turbo build

I really wanted to build a turbo bike after seeing a few about at meets. I was planning on selling my 12 and buying a bandit to boost. Then I came across "budget turbo build" on this forum which gave tons of brilliant info and it looked cheaper/easier in my view.
After a bit of research I decided to keep the 12 and turbo it.
So sized a turbo using the garret app. Then picked a cheap one of eBay that had a similar map and ended up with Volvo td04-13t.
This is a small turbo with wastegate and blow off valve integrated into the compressor housing.



Got this for 50 quid off eBay.

Then these zx14 injectors for fueling for 15 quid. Proper bargain.

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post #2 of 46 Old 06-02-2016, 04:59 PM Thread Starter
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The aim is to keep the turbo up nice and high and return the oil back into the side of the sump without the use of a pump, and not remove/relocate the oil filter/cooler. After removing my muzzy exhaust I positioned the turbo and worked out some angles and positions.






Then I positioned it in a final location after looking at the exhaust run and the inlet through the fairing and made this.














I am not a welder, but I made and shaped all the sections to fit. Happy with the position. Short radius 1.5 inch stainless bends and some straight pipe. Flanges are mild steel. I would make the cylinder head flange from thicker 5-6mm plate instead off 3 if doing it again. 3mm distorts to much.

Last edited by Bigcj; 06-02-2016 at 06:06 PM.
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post #3 of 46 Old 06-02-2016, 05:12 PM Thread Starter
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Pulled the turbo to bits and it all looks good. Rotated the bearing housing etc to get the angles needed to line it all up and T water feeds in the position.





Cut a flange and got some 3" stainless exhaust to come straight off the turbo and follow the path of the original pipe back.

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post #4 of 46 Old 06-02-2016, 05:15 PM Thread Starter
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Fits OK.
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post #5 of 46 Old 06-02-2016, 05:19 PM Thread Starter
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Removed the sump and drilled and tapped the sump for the oil return.



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post #6 of 46 Old 06-02-2016, 05:22 PM Thread Starter
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Put everything together. Got a oil feed line made. Pulled the 3/8 plug from the oil gallery opposite side to the oil pressure sensor. I drilled and tapped a 3/8 plug with a 12mmx1.5 tap for banjo fitting to match the turbo. Hose has same 12mm banjos each side.

Plumbed into the water feed to the oil cooler. For the water feed to the turbo.

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post #7 of 46 Old 06-02-2016, 05:29 PM Thread Starter
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Made some little top hats for injectors. And refitted them into the fuel rail.



Switched round the wastgate actuator to the exhaust side and made a bracket to mount it. I had to cut the arm off the waste gate on the turbo and weld it back on 180 degrees around to make it fit.



Blocked off the holes in the plenum




Last edited by Bigcj; 06-02-2016 at 06:08 PM.
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post #8 of 46 Old 06-02-2016, 05:33 PM Thread Starter
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All seems to fit together. The eBay 2-3 inch elbow came in handy. 2" 45 elbow.

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post #9 of 46 Old 06-02-2016, 05:40 PM Thread Starter
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Fitted uprated fuel pump.



Bypassed the OEM fuel pressure regulator with this.

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post #10 of 46 Old 06-02-2016, 05:45 PM Thread Starter
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Has turned out nice.





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post #11 of 46 Old 06-02-2016, 05:46 PM Thread Starter
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Quick vid of it running. Now its time to tune it with the pcIII USB.

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post #12 of 46 Old 06-02-2016, 06:46 PM
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Nice work!

I hate stupid people.
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post #13 of 46 Old 06-02-2016, 09:42 PM
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Garage
Nice work !
Bike looks pretty neat !
Have you ridden it yet?
What was your final budget?
-Dave :-)
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post #14 of 46 Old 06-03-2016, 12:05 AM Thread Starter
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Cheers lads. I reckon it was close to 420 quid. I didn't buy the power commander. It was already on the bike. Biggest cost would have been the manifold and exhaust but these where fabbed at work. The turbo and injectors where proper eBay bargains.

I have ridden it. It turns some heads. Its not been past 5 k or 20 % throttle as still tuning. The map is Rich as boost is starting to climb I am getting 9.0:1 AFR so I back off.

Last edited by Bigcj; 06-03-2016 at 12:16 AM.
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post #15 of 46 Old 06-03-2016, 01:36 AM
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Very cool build, nice job

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