GS500 build thread... cf tanks, internal supercharger, etc

[mllcb42]

Been working on getting everything mocked up on the bike.

Was planning on using the space between the subframe rails to place the ecu, etc... but this didn't actually leave anywhere for the rear tire to go when the suspension compresses.

With the stock rear fender in place it's obvious I have a serious shortage of space.

I don't have any intentions on ever running a passenger on the bike, especially since I've shortened the rear subframe and removed the passenger pegs, so I'll make some room in the seat itself. No need for any foam for the passenger to sit on, so I'll make a carbon seat cowl and remove all the seat foam and supports below it, giving me a place to put the ecu.

A well stretched trash bag over the seat provides a nice smooth surface, protects the seat for resin, and separates easily after the part dries.

An hour or so later, covered in fiberglass.

 

[Stormdragon]

A well stretched trash bag over the seat provides a nice smooth surface, protects the seat for resin, and separates easily after the part dries.

Smart man! I'm stealing that idea. Um, if I ever get around to any of the projects I like to think about doing that is.

 

[mllcb42]

Smart man! I'm stealing that idea. Um, if I ever get around to any of the projects I like to think about doing that is.

It's honestly one of the easiest ways to get started in making fiberglass parts. Requires very little effort, is really hard to screw up, and always produces a decent product.

 

[R3DS!X]

Thread continues to be awesome.

 

[mllcb42]

So what do you do when it's too cold outside for the resin to cure but you have work to do?

Revert to your fort building days of your childhood!

chairs + blanket + space heater=

The FortOven

cf tank getting the two halves joined and the cf seat cowl curing

 

[ithaca00]

This thread has copious amounts of awesome! I'm patiently waiting every update!

 

[bikeama]

First thread I have subscribed to. Can wait to see it run.

Bill

 

[mllcb42]

I've been contemplating using an intercooler for my air tank for several month. Unfortunately, finding an intercooler small enough is a bit of a task. Finally got some dimensions on one of the smallest factory intercoolers available. This is from the mazda millenia. Apparently they run two small intercoolers.

Unfortunately, the size is still on the large side for a bike. So I made a foam mock up to see if I could find somewhere it could fit.

This is about the best place I can find. Not sure how I feel about it.

Also picked up some foam today to start working on an idea I've had for some time for making carbon fiber charge pipes for the intake. I made a little 4" long section to test it out. We'll see if it worked or not after the resin cures.

 

[mllcb42]

CF charge pipes? yes please!
So the new method works as it should.

From foam to pipe in about 5 hours... not bad at all.

 

[det5lonewolf]

The aft reed valve is temp mounted backwards, yes?

 

[R3DS!X]

What about having the intercooler under the bike and have a air scoop?

 

[mllcb42]

The aft reed valve is temp mounted backwards, yes?

Nope. That's the intake reed valve. There's also a reed valve mounted on the exhaust port facing the other way.

 

[mllcb42]

What about having the intercooler under the bike and have a air scoop?

not enough space/clearance anywhere along the bottom of the bike

 

[R3DS!X]

under the frame? are you gonna put plastics on or something?

 

[mllcb42]

under the frame? are you gonna put plastics on or something?

Was planning on running the exhaust under the bike. The intercooler is a good big wider than the frame at the bottom as well. I'm concerned if I were to put it there, I'd run into ground clearance issues while turning.

 

[R3DS!X]

i see. i didnt read of you underslung exhaust plans.

 

[mllcb42]

i see. i didnt read of you underslung exhaust plans.

I may not have posted them. Here's what I was thinking

seat cowl rough cut. Still need to tidy it up.

been playing with the idea of putting the intercooler under the seat cowl and ducting air in

It'll fit, but it's a low pressure area so some creative ducting would be needed to make it work. We'll see.

 

[mllcb42]

cf pipes look like they'll work well

 

[nadrojp]

moto boner...dont stop...oh oh...

 

[mllcb42]

Can cf handle that?

Absolutely. Hell, look at the 80's turbo f1 cars running carbon intake manifolds. This is far less stress and far more modern materials. (Assuming you're talking about the charge pipes)