Blow through suzuki 1.3
 

This is my samurai. Its still a huge work in progress but I did finally get it to make hot water last night.
I have been messing around with them for a while and have always been really happy with how they wheel but have never liked the output of the engines. So I have been trying some differnt things.
http://img15.imageshack.us/img15/5909/picture433.th.jpg
http://img509.imageshack.us/img509/2...ture422.th.jpg
http://img14.imageshack.us/img14/6861/picture434.th.jpg

My first try at getting the motor to run better was just trying to do what evryone else pretty much did. I ran the 1000cc 3 cyl pistons wich are flat tops, (everyone says they are higher compression then they are, with the pistons down the hole 15 thou the actuall compression ended up being 9.2) I used a 1.6 8 valave tracker head and a calmini header, it uses a larger valve and port. I also used a hawk cam. My original dyno sheet made a whopping 40rwhp with the 30 inch tires. After this build I made 48hp. I swapped on a weber and while it made really good power it absolutely sucked off road.
It stalled ascending really bad, turning it around helped climbimg but made decending just as bad. So I tried a setup useing gsx600 suzuki carbs and a custom manifold I made to mate them to the head

http://img509.imageshack.us/img509/1...ture580.th.jpg
http://img54.imageshack.us/img54/3521/picture585.th.jpg

The carbs worked great, no drivabilty problems, way better power above 5K and they never stalled, even on some hardcore climbs, even rolled it onto its door and it stayed running, so that part was a giant step in the right direction. I dyno'd the new setup too and it made 74hp at 7K. Wich is 1500 rpm more than with the crappy weber. The extra revs really helped get the rig onto the freeway. So anyway I decided that I wanted to try to turbo the damn thing I got a audi 1.8 turbo from a friend, built a manifold and a inlet plenum for the carbs and put it together
http://img54.imageshack.us/img54/7388/picture611.th.jpg
http://img134.imageshack.us/img134/2615/1000860.th.jpg
http://img15.imageshack.us/img15/7128/1000844.th.jpg
http://img223.imageshack.us/img223/2311/1000869.th.jpg
Anyway, I got it running but I still need to do the fuel system for it, I'm useing a aeromotive regulator, return line, and a walbro inline pump. I'm also going to use a msd 6btm to retard v. boost. I'm trying to get my act together as far as tuning goes before I dive all the way in. I have boost ref'd the carbs float vents, and have filled the floats with foam so I'm about ready to give it a reall try. Has anyone here meesed with these things at all? I would really appreciate any help or insight in terms of things to look for.

Re: Blow through suzuki 1.3
 

awesome :D

Re: Blow through suzuki 1.3
 

webers love boost. what model is the carbs? google the model and with words like 'turbo' or 'boost' and see what you get...

Re: Blow through suzuki 1.3
 

I hart samis, welcome!

Re: Blow through suzuki 1.3
 

Holy Santa Clause ---- that is ------- tits. I love samurais! Always wanted one

Re: Blow through suzuki 1.3
 

Nice, I have always wanted a tin top. I have had an sj410, and a soft top sami, but never the tin.

Looking forward seeing how this turns out.

Re: Blow through suzuki 1.3
 

Bad ass

Re: Blow through suzuki 1.3
 

Can't wait to see this thing in action. Very cool 8)

Re: Blow through suzuki 1.3
 

i've never messed with itbs, but if they are anything like an old school 4brl, then solid floats, bigger jets and your golden

build looks tits. throw up some stuff on what you've done to the chassis

Re: Blow through suzuki 1.3
 

What suzuki carb's are they Kehin vacuums? And really nice job on that Intake P, but really where's the rest of the shots of the e-manifold with that K03 hangin on it and the down pipe leaving it? Did you fab that stuff up as well? And really, while you're at it, Don't you think you should fab up porn to go with this "mock-up".

Re: Blow through suzuki 1.3
 

ha awsome build, good luck

Re: Blow through suzuki 1.3
 

sick build man!!

looks like you could work a DSM or audi sidemount in there for a little more efficiency

Re: Blow through suzuki 1.3
 

nice build!

an air-air cooler might not work well offroad, the speeds are usually low. Maybe the rad fan would draw enough air, maybe not though. Water-air ought to do the trick though.

Re: Blow through suzuki 1.3
 

Awesome build. What else do you have done to it?

Re: Blow through suzuki 1.3
 

awesome Samurai! should be pretty fun

Re: Blow through suzuki 1.3
 

this picture is BADASS
http://img15.imageshack.us/img15/5909/picture433.jpg

Re: Blow through suzuki 1.3
 

Sorry, didn't get the best pics of the exh manifold but this is what I took before puting it on. Its all up and running now, still need to finish building the fuel system but I hope to do it by this weakend, I have everything and even got the fuel lines bent out of 3/8" hardline, so its moving forward.
The down pipe is just a 3" u bend thaat gets the exhaust out of the engine bay. I still havn't built/finished the peice that attatches to the old exhaust. Its realy not a mock up, as it sits not much is going to come off again. I will finish the new bits but its pretty much a done thing.
http://img23.imageshack.us/img23/1064/picture613.th.jpg
http://img144.imageshack.us/img144/1...ture612.th.jpg
http://img144.imageshack.us/img144/7...ture611.th.jpg

As far as IC stuff goes, I don't expect to see much, if any boost offroad, so airflow is less of a concern than it could be, and I installed a relatively large (for the power level) front mount.
http://img144.imageshack.us/img144/2...ture594.th.jpg
http://img178.imageshack.us/img178/296/1000868.th.jpg
The carbs are 600 gsx carbs, off of a 98.

The chassis is pretty simple, ford f250 front shock mounts, pro-comp shocks, spring over pads, metro brake lines, tracker front 3rd member, tracker/sammy hybrid rear, 4-1 t-case, driveline spacers, The rig works great off road, it has a spool in the rear and a lock right up front. Driving it right now without the fuel system sucks, it used to honk pretty good NA, but it runs like poop right now. So the fuel system stuffis top of the priority list. I have a 85 front toyota housing and a 07 toy tacoma rear end that looks wide enough to off set the rear housing properly without much work to the long side. But like I said thats down the road.

Thanx for all the positive input guys.

Re: Blow through suzuki 1.3
 

Nice job on the mani. How thick are those tee's and ell's you used? Do let us know if you have any cracking problems.

The carbs are 600 gsx carbs, off of a 98.

The reason I asked if those carbs where vacuum is: after looking at your plenum, I got to thinking about my 1000r Kawasaki with a K03 on it. You see where I'm going with this.

Re: Blow through suzuki 1.3
 

you should make boost pretty early on the vw it came off of it makes starts making boost at 2500 rpm's in 3rd or 4th gear but they are damn good turbo's and can take a beating, people with them on vw run as much as 25psi dropping to about 13 psi at redline and with a drop in filter and turbo back exhaust and chip they are good for 250-260tq and 210 whp
hell i've got a stock vw intercooler laying around wanna make an offer i don't need it i have a front mount now

just becareful because i think it'll make boost before you think it will but if you keep it to about 10 psi it won't blow air that is too hot that's in its 70% or higher efficiency range

Re: Blow through suzuki 1.3
 

pimp build, were any samies fuel injected from the factory?

Re: Blow through suzuki 1.3
 

I grafted one onto my 1.6 sohc (mazda) and it makes boost fast at as little as 2500 in second gear. I'm only running it up to 6 pounds, stock internals and all. Yeah, I was surprized to say the least.
Show a pic of the intercooler with a tape measure so I can get some sense of dimensions.
I'm running a "Coolingmist varicool II" right now to control the top end.

Re: Blow through suzuki 1.3
 

Boosted samurai FTMFW! I seen one here mud riding one that was on 35's, 10 PSI w/ WI. Not even four-wheelers could go where he went. He ended up breaking both new front hubs and got stuck. We pulled him out and he ------- drove in 2WD out of this valley that I don't think anything else before him has ever left out of without 4WD or a cable pulling them up. He was in 3rd gear boosting moving forward about 1/2 mph up that hill. I thought he was gonna light the tires on fire. Was the coolest ---- I've ever seen. I've always wanted one to build and boost. They're sick.

Re: Blow through suzuki 1.3
 

sweet are you running a pressurized regulator so fp stays ahead of boost? any 1:1 ratio works and the book torbomania by bob tomilsone written for turbocharging aircoold vw has lots of stuff how to prep a carb for blow throw (tahts where i started boosting before hmt :y old school air cooled :7)

Re: Blow through suzuki 1.3
 

I have the regulator, and am working on getting it installed and setup still, worked on it tonight a bunch, got the msd 6btm installed and mostly wired, still need a few bits and pices to finish that part up. Got the fuel lines bent and installed to the rear axle but still need to pull the tank and get a through fitting for the return and get a bigger feed tube in the pickup.

The bike carbs are gravity fed I'm pretty sure, so I need to be spot on with the fuel pressure. So I'm running a 5/16 feed and a 3/8 return line. This will make damn sure that the fuel pressure regulator will be able to control pressure properly. I just don't want to have a issue with too much fuel pressure at low loads. I'm running a inline pump from the ranger as its pretty low flow. I'll let you know how it works but anyone have a pump in mind that you think would work ok?

The manifold ells are the vibrant schedual 10 stainless ones. I have a bunch of the manifold flanges too so if you know anyone who needs/wants one. I have about 40 bucks into them. I also have a bunch of the ko3 turbo flange still if anyone is looking. They are both 3/8 stainless water jetted.
As far as cracking goes I know it will eventually but am hoping to get some miles out of it. I am a servicable welder, I can tig ok and mig allright. I'm no pro, but my stuff usually doesn't randomly explode. Aluminum still kicks my ass every now and then, my consistancy is in need of work, but I'm getting there. The inlet plenum turned out better than it should have concidering my abilty, but I'll take it.

As far as the boost threshold goes, that would be great if it lit early, but my real reason for the turbo in the first place is freeway driving to and from the wheeling areas, i'm tired of hills kicking my ass. This is truly one of those few times were the turbo is being added because of need not just want. Anyway, thanks again for the help and warm fuzzy ----. I got some great action shots from the last wheeling trip I will try and post here in a bit.

Re: Blow through suzuki 1.3
 

I'd be interested in a couple of those k03 flanges. I'd want one of the 3 bolt, going into the turbine, and the 3 bolt flange going out of the turbine (for downpipe). It's a 3 bolt out of your turbine no? I know KKK also has a 4 bolt k03/k04 as well as the 3 bolt. The downpipe I fabbed coming out of my k03 is a 2"od, but it looks like you maybe did a 2.5" hole?

Re: Blow through suzuki 1.3
 

Actually, the outlet on this turbo is a strait 3" opening. Its almost the same a standard 3" 3 bolt header flange. I got my 3 bolt flange from vibrant. It was 18 bucks I think. The turbine inlet flanges turned out pretty nice. Pm me your adress? I will post the actuall part number from vibrant tomorrow. I had to file the holes out about 30 thou. and I think I needed to drill the holes out to 7/16 but it worked perfect. I don't run any gaskets, I just made real sure the flanges and head were flat and clean. No leaks so far. I got a bit more done on the sammy tonight. Still got to drop the tank and do the mods there and mountthe pump, but I am closer.

Here are some pics of the manifold I built to mount the carbs to the head. Its simple but it works.

http://img3.imageshack.us/img3/6549/picture589.th.jpg
http://img3.imageshack.us/img3/3982/picture590.th.jpg

Like I said, simple.

Re: Blow through suzuki 1.3
 

looks sweet why is that hose there .. circulate water throw the intake manifold .. per heat??? sorry cant really read right now..

Re: Blow through suzuki 1.3
 

http://img27.imageshack.us/img27/7310/pn7d.jpg
http://img140.imageshack.us/img140/9001/pn2.jpg
http://img187.imageshack.us/img187/8411/pn5.jpg
http://img187.imageshack.us/img187/pn5.jpg/1/w160.png



No, not preheat, the water flows throught the manifold before the t-stat houseing. The tubes are because I made the manifold on a peice of ---- chink drill press that wouldn't drill a stait hole toave it from the nippon trash heep, so I ran the water externaly instead of drilling the passages internally like was my first idea/desighn. Currently I have access to a decent cnc machine and have solved that issue, so I can make new manifolds with the water passages inside instead of the tube arrangement. Either works, and the external tubes looks way more hmt.

Re: Blow through suzuki 1.3
 

Those are mikuni snowmobile carbs man. Webers aren't that good and they take a lot of time and preparation to pressurize and get ready for boost. These mikuni's are far easier to use.

Nice build dude.

Re: Blow through suzuki 1.3
 

don't tell him or me what carbs he doesn't have. i posted webers because at the time of posting i did not see he stated what they were (look like sidedrafts anyways)

now ---- off and post something other than trolling useless information

Re: Blow through suzuki 1.3
 

Whats your problem? take it easy man. The carbs are very similar to what are used on sleds, i didn't see that he put from a suzuki 600, but they are still Mikuni's.

Re: Blow through suzuki 1.3
 

Yep they are 32mm kuni's. I tried a set of 36 mm off of a gsx 750 but they didn't really work any better and the 32's I had pretty dialled in already. I ended up running some rather large jets to make it work well na. The jetting trial and eror actually got pretty spendy so a pin vice and some bits have since replaced the jet ordering-athon. My best performance ended up being a jet with the same dia as the 160 jet, but due to tolerance dif's and the inlet/outlet radius differences between a 10,000 dollar bad ass jet makeing machine and my half tipsy ass with the pin vice wedged in the makita, I can't claim any consistancy at all. Another really cool thing I tried was puting a wide band bung in each primary. Wow, was that a great learning experience. I only have a single wb channel, so I had to make 4 runs back to back and overlay, but it was really cool. The single biggest variable in any of my "testing" (aka totally ------- off) was air cleaner desighn. The right cleaners really made a huge diff. But that makes sense as when you buy a air cleaner kit it comes with jetting for the bike and aplication.

I'm heading dwn to the shop toaday to get the tank stuff finished. I pulled it yesterday and need a new through fitting and mount the pump. We'll see, I'll post what I manage to figure out. I Hope this works.The more I ---- with it, the more I'm tempted to MSI the stupid thing useing the gsxr ITBS and injectors and get on with my life.


Anyway, have a good weakend fuckers

Re: Blow through suzuki 1.3
 

Just out of curiosity...what was the recommended jetting for that bike and filters? I am wondering how far off it would be from the jets you used, since carbs work off of vacuum, I would think it would be similar.

Re: Blow through suzuki 1.3
 

So i'm getting my ass kicked. I have got the fuel system done but its still not the way the motor wants. I've taken a extra set of carbs apart and can't find any way that a blow-through won't work properly, yet it flat don't work. I still have a few things to try but to be honest, i'm getting a bit discouraged. I am a long way from giving up, but it didn't responjd at all the way I though it would to the nw fuel system. I need to get the downpipe done so I can get a wide band in the exhaust, but i'm 99% sure it just goes dead lean under much load. So if you have any insight, throw it out there. Thanx guys.

Re: Blow through suzuki 1.3
 

send a pm to tough-guy he has a turbo bike....


and he works on recreational/sport stuff all the time.

Re: Blow through suzuki 1.3
 

Waiting for some ripper vids.

Re: Blow through suzuki 1.3
 

seconded. For this unique setup, I require both on-road and off-road rippers.

Re: Blow through suzuki 1.3
 

I've got a water/meth injection system on my set-up (fuel injected 1.6 sohc w/ k03), You can set it to come at x amount of boost with x amount of spray and then increase as you want when you want. It's a "Coolingmist Vari cool II". Here's a pic of the cuntroller:
click it to enlarge
http://img91.imageshack.us/img91/3913/PICT13.th.jpg

Re: Blow through suzuki 1.3
 

SO I swapped in the 195 jets and bam, we got action. I also fixed a problem with the float vents and now its much much better. Got it actually rev to the limiter. I got the downpipe installed with the wide band bung, I didn't get the sensor in it to really get any data yet, but I will tomorrow. I will get some more info and seat time tomorow and try to get an idea of where i'm at, but so far so good. I think I'm over the hump though.

WOOHOO

Alright, I don't have a ripper yet, but its on the way for sure. But I have put a few miles on the rig in the last few days, enough to get the neighbor bitch to call the heat on me. So far, thing runs very well. I ran the wb and got 12.2-12.3 at wot at the top of the revs in 3r gear, so I'm close. I would like to see a touch richer for safty sake, but so far no issues. My drivability needs a bit of work, I need to change my needles I think as my tip in, and "early" part throttle afr is still too lean. I think I'm going to try and carve up my own needle profiles with a drill and some sand paper. Maybe a file. With the 195's it idles at 12.5, wich is too rich, but it still runs pretty damn good at idle.
Things I learned so far.
the carbs facory are jetted 115 on the gsx 600 motor
my best performance on my engine was with 160's NA.
the carbs work good under boost, but they need a pretty big delta across the slides before they open, this has caused problems with some of my boost referenced gear like the btm and fuel pressure regulator, and I have had to move some of the ports around to get good, reliable, accurate signals.
with the big jets the choke is very comanding, able to soak the plugs if not careful.
The fuel pressure requirements are almost nil. If I could get fp to be 1 to 1.5 psi above boost it would be enough. In fact with my regulator, the floats are so lightly sprung that pressure ocilates between 1.5 and 2 psi as it blows the needle open regularly if I'm off on the adjustmant even a smidgen
I have thought about modifying a egr valve position sensor from a ford to run on the top of the carbs so I can know were the slide is at all times and log its position on the dyno or a logger.

Rippers, on road, off road and dyno comeing soon.