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Author Topic: Nannos Hotrod Turbo TR1.1 (XV1000)  (Read 4277 times)

Offline der_nanno

  • Posts: 498
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #10 on: Dec 08, 2018, 18:06:20 »
Slowly, but steadily this stuff's coming together like it should... to admit I am a bit excited by now is a wild understatement. It all seemed rather theoretical up to now, but by now it's basically down to finishing the oil-suppy and then find out which parts I robbed off the bike in the last one-and-a-half years. But I am getting ahead of myself.

First step was to clock the turbo, which is a dead simple job on a new turbo, but a lot less so, when years of caked on oil and diesel-soot glued the whole lot together for good. Weeks of penetrating oil, a heat gun and some (not overly) gentle taps with a Newtonian particle accelerator (a PROPER rubber mallet) and it finally freed up. And just to give you an idea, just how small that lil' turbo is that's a 10mm spanner below it.



Following the tradition of this being a proper parts-bin-special, this is a wastegate actuator from some Volvo (I think) with a GT1752 as the original actuator worked from vacuum and not boost, because it was operated by the Opel's ECU and not directly. (They were waaaay ahead of their time back then...)



 bit of fitting up of all the components and that VERY satisfying moment of: it's tight, but all fits in there... somewhere.



From a design point of view, this has got to be the single most elaborate plenum/intake manifold, I have designed to this point. It's every bit as three-dimensional as you would think, when looking at these pictures.



And that's actually the fabrication side of things on the cold side of the turbo mostly done.





So what's still missing at this point: I have to drill and tap the compressor housing to get a boost-source for the wastegate-actuator, sort out the oil-lines (both feed and drain), tap the engine case for the oil-supply and then sort out all the electrical gremlins that mostly stem from me "borrowing" parts for my daily and friends' projects.

I do not see a silencer as a high priority item.   ;)

Blog: https://greasygreg.blogspot.com/2018/12/the-turbo-tr1-new-manifold-part-4.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 Kunipshun Fit

  • Posts: 48
  • Big Dreams. Small Funds!
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #11 on: Dec 23, 2018, 15:51:21 »
Well damn.  This is cool!
Lurker and dreamer.  Maybe one day Ill start on my bike.

Offline der_nanno

  • Posts: 498
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #12 on: Dec 24, 2018, 04:40:22 »
Bit of a slow burner at the moment, as I blew a tyre out on my car and some f*ckwit played around with the brakes on my sidecar (second daily this time of the year), so I had to fix those first and that was shed-time used up. But to be fair, some updates in the making and the first start isn't too far away anymore as well.

Cheers,
Greg
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: 498
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #13 on: Apr 13, 2019, 17:35:39 »
It's admittedly been more than just ages...  >:(

In very short: drilled and tapped the block at an unused boss, which looks a lot like it was orginally meant to be an oilpressure pickup anyway.





Changed the oil and all starter components (solenoid and starter as 38 years of carbon buildup killed the old starter) and then it was about time to push the button and spin the engine over and see if the oil-supply to the turbo works...



The long(er) version of this is on my blog: https://greasygreg.blogspot.com/2019/04/the-turbo-tr1-turbo-oilfeed-and-new.html

The following updates should (admittedly) not make you wait for three or four months between each post.
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: 498
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #14 on: Apr 19, 2019, 14:40:20 »
I'll just leave this here...  8)

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: 498
  • Faster!
    • Greasy Greg
Re: Nannos Hotrod Turbo TR1.1 (XV1000)
« Reply #15 on: May 10, 2019, 12:57:08 »
Right, progress is sluggish as in reality I have mostly been working on my XS Triple Sidecar to get that fully functional as to be honest, this is a bit more important in day to day life. BUT as the flatslide carbs on the triple have fought me all the way and I needed a break, I gave it a well-deserved shot to make some progress...

Step one was to get the wastegate working, which meant giving the wastegate actuator a boost-reference. As this turbo originall came off a 2.0 litre Opel (Vauxhall) Vectra Turbodiesel and contrary to what most people think about those diesels, they already sported electronical boost management (in the late 90ies), the turbo needed some modifications.




... and even though it was a nice press fit, a bit of epoxy wouldn't do harm.



The bigger issue (for me) was the oil-return, as some numpty put the downpipes right below the turbo thus making the whole fabrication of the oil-return a slightly more elaborate task as unlike in version 1.0 a simple bit of heavy duty rubber hose just won't do.



As I was curious to find out, whether all the rumours about oil-return sizing and the fact that it ABSOLUTELY had to be perfectly vertical etc. and blablablabla, I though I gave it a shot... and guess what, the old girl fired straight up, even though there were one or two leaks around the manifold that still need addressing.



The exhaust tubes are a bit restrictive as can be seen by the lovely exhaust colours.



... and there's quite a bit of improvement in the 2in1 manifold, even though the boost gauge has taken a hit in the past and 0.5 Bar (7PSI) is actually. But still 0.2 Bar of boost at idle means a restriction of 3PSI, which quite frankly is A LOT.



Everything even held together well enough for a proper lap in the yard and the engine lasted the complete 1/4-mile in a single go...



At the moment I am working on making a mount for the seat and also tucking away all the small bits like solenoids etc. to make the whole bike look a bit neater. Not exactly the glamourous stuff, but it has to be done eventually.

Blog: https://greasygreg.blogspot.com/2019/04/the-turbo-tr1-oildrain-and-first-start.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