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Author Topic: Nannos Hotrod Turbo TR1.1 (XV1000)  (Read 2156 times)

Offline der_nanno

  • Posts: 408
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    • Greasy Greg
Nannos Hotrod Turbo TR1.1 (XV1000)
« on: Dec 31, 2016, 19:16:26 »
I've promised, I open a thread on my turbo and it's probably one of the last things I'll do in 2016, but hey... rather late than never, right?

Well to be honest, the whole story started about two years ago, when I "bought" the bike for a crate of beer. Mainly because the engine was seized (the p.o. had pulled the carbs and then part of the roof of his workshop collapsed) and well... just check out the pictures, which make the bike look A LOT nicer than it actually was. Lots of parts simply turned into dust at the lightest touch.

Technical specs of this one:

XV1100 crank to bring it up to 1063cc
Stock XV1100 heads with polished valves and slightly ported (just taken off the casting imperfections really)
modified TR1-clutch or maybe a modified XV1100 clutch (that would allow an extra 9th disk)

There's actually two turbo setups you can see in the pics and a third one to be built soon.

1) The blow-through-setup consists of stock XV1100 Mikuni carbs (because they have very heavy slides and external floatchamber vents), a TD04-13G turbo (out of a Subbie Forester), Intercooler out of a Ford Focus Turbo Diesel, fuel pump BMW 528i E39, fuel pressure regulator: a cheap one made out of Chinesium - I've never quite finished this setup due to some issues with the TD04, but quite a large portion of it will be used for the new setup with a GT1548

2) A rather butch and simple draw-through setup with a Chinese Garrett T3 copy and a Mikuni VM44 on a 2in1-manifold. There's absolutely nothing fancy about this setup, but it worked until a bearing failure stopped the turbo dead.

So here we go:





























































Then I had some flanges cut for the first turbo-setup:



And this is pretty much, where the build for the first version of the turbo setup ended:














Then I started on the draw-through setup:



















And that's the headers sorted:




Clocked the turbo and took off some measurments:



Used an old brake-line to work out the correct length: (35cm)


Getting the rear header right:






The finished product (admittedly the front-downtube is only tacked at that point, as I ran out of time)




And that's what she looked like in the end:




And there she's runnin':


Now you have to be patient with me as I am currently building a new sidecar for me (XS750 with a KMZ/Dnepr K750 sidecar) and well, I can't "just" build a sidecar... (and I am way behind schedule, but that's how life goes!)

I admit I've left out some bits and those can be found on my blog in the following posts (as I said, this has been going on for two years, even though only a fraction of the time was spent on building the turbo setups, but I mainly used the bike for building exhausts for my own and other TR1s/XV750ies)

http://greasygreg.blogspot.co.at/2016/0 ... art-1.html
http://greasygreg.blogspot.co.at/2016/0 ... bling.html
http://greasygreg.blogspot.co.at/2016/0 ... g-out.html
http://greasygreg.blogspot.co.at/2016/0 ... er-of.html
http://greasygreg.blogspot.co.at/2016/0 ... s-are.html
http://greasygreg.blogspot.co.at/2016/0 ... alves.html

Cheers,
Greg
« Last Edit: Feb 14, 2017, 16:57:03 by der_nanno »
Real freedom starts with the freedom of thought.

My Blog:
http://greasygreg.blogspot.co.at

My Mule TR1.1 build here on DTT:
http://www.dotheton.com/forum/index.php?topic=75458.0

My Turbo TR1.1 (XV1000) build here on DTT:
http://www.dotheton.com/forum/index.php?topic=72571

My XS Triple Sidecar build here on DTT:
http://www.dotheton.com/forum/index.php?topic=74211

Offline der_nanno

  • Posts: 408
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #1 on: Jan 22, 2017, 06:08:17 »
Thx to Beachcomber for reminding me of the existance of CT20 turbos (and the fact that some of them in fact truly ARE carbon sealed, I had a little poke around the mighty bay of "e" and guess what - I found an early CT20 turbo in good nick for the right price. The whole thing isn't gonna be quite as straight-forward as I hoped initially as you can't clock CT20 turbos and feed and drain are on the same side. Those aren't real show stopper, but it means a little obstacle that I will be forced to work around.
« Last Edit: Feb 14, 2017, 16:59:49 by der_nanno »
Real freedom starts with the freedom of thought.

My Blog:
http://greasygreg.blogspot.co.at

My Mule TR1.1 build here on DTT:
http://www.dotheton.com/forum/index.php?topic=75458.0

My Turbo TR1.1 (XV1000) build here on DTT:
http://www.dotheton.com/forum/index.php?topic=72571

My XS Triple Sidecar build here on DTT:
http://www.dotheton.com/forum/index.php?topic=74211

Offline der_nanno

  • Posts: 408
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #2 on: Mar 15, 2018, 13:12:52 »
I guess, this thread has lain dormant for a sufficient amount of time, so I might as well, start it off once more.

Now I had a rather nice turbo setup on the bike, unfortunately said turbo died. Then I got my dirty ol' paws on quite a nice Eaton M45, but unfortunately, no matter how I twisted and turned it, it would have meant raking the headstock to make the supercharger fit between front-wheel and engine.

So when a friend told me, that his old Jeep Wrangler with the (in-)famous IL-6 needed a supercharger I sold said Eaton M45 and made a few adaptors for him.

Fast forward a couple of weeks (months actually) and I was able to get my hands on a VW-branded Eaton M24 out of a 1.4TSI Polo.



Due to the internal step-up gears with a 1.93:1 ratio, this little blower actually displaces 46.3ci per revolution, which means it actually puts out more air than the old M45, even though at the cost of producing more heat at the same time.

I already have sketched up an adaptor for the crank, but I have to get a LH-M8 tap (easy) and a LH M8x40 bolt (the actuall challenge as I found out) to secure said adapter to the crank.

Bit more stuff on my blog: http://greasygreg.blogspot.co.at/2018/03/the-turbo-tr1-maintenance.html
Real freedom starts with the freedom of thought.

My Blog:
http://greasygreg.blogspot.co.at

My Mule TR1.1 build here on DTT:
http://www.dotheton.com/forum/index.php?topic=75458.0

My Turbo TR1.1 (XV1000) build here on DTT:
http://www.dotheton.com/forum/index.php?topic=72571

My XS Triple Sidecar build here on DTT:
http://www.dotheton.com/forum/index.php?topic=74211

Offline der_nanno

  • Posts: 408
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #3 on: May 10, 2018, 02:57:49 »
Now being a curator of all manner of things being special, i.e. being a hoarder of my old projects, I still had an earlier set of turbo headers kicking about and as I recently had to wait for some spare parts to be delivered for the new TR1 engine, I did some measuring on a flange, only to discover that said flange could be repurposed.



Now almost nothing drills as "nice" as work hardened stainless steel, so drilling three holes took the better part of two hours and an ungodly amount of swearing.



But after a bit of dressup with an angle grinder and a flap-disk, the result is almost presentable.



The turbo in the picture doesn't only LOOK, but actually IS tiny. It's a GT1540-something, out of a Opel Astra 2.0 Turbodiesel, which makes a bit shy of 100hp.





So why go down from a GT30 to GT15? The answers are: instant boost and I had it already sitting on the shelf gathering dust. As some of you may, is this the end to the supercharger project? No, but I can get this buttoned up and working in a matter of days and then have some fun on it and the supercharger is a genuine engineering challenge and will require a bigger time investment than I currently have available. (And the everyday engine is more important for obvious reasons...)

More-pix here: http://greasygreg.blogspot.co.at/2018/05/the-turbo-tr1-gt15-turbo-build-part-1.html
Real freedom starts with the freedom of thought.

My Blog:
http://greasygreg.blogspot.co.at

My Mule TR1.1 build here on DTT:
http://www.dotheton.com/forum/index.php?topic=75458.0

My Turbo TR1.1 (XV1000) build here on DTT:
http://www.dotheton.com/forum/index.php?topic=72571

My XS Triple Sidecar build here on DTT:
http://www.dotheton.com/forum/index.php?topic=74211

Offline Brodie

  • DTT SUPPORTER
  • *
  • Posts: 2309
  • Gold Coast, Queensland
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #4 on: May 10, 2018, 08:40:55 »
Twin charge sounds good.
I'm not sure, but don't ask Brodie.

Way to many build and half done projects to list here.
Sr250, Gs750, Z50A, XV1100, A10, Z160A.

Offline der_nanno

  • Posts: 408
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #5 on: May 10, 2018, 09:06:11 »
Ultimately I want to register this heap for road use, so Supercharger it is... The authorities are straight from spoil-sport-land.
Real freedom starts with the freedom of thought.

My Blog:
http://greasygreg.blogspot.co.at

My Mule TR1.1 build here on DTT:
http://www.dotheton.com/forum/index.php?topic=75458.0

My Turbo TR1.1 (XV1000) build here on DTT:
http://www.dotheton.com/forum/index.php?topic=72571

My XS Triple Sidecar build here on DTT:
http://www.dotheton.com/forum/index.php?topic=74211