Ducati HyperMotard Turbo Project - www.Motorcyclebuilders.net

DucCutters · #1 05-27-2009, 17:32

Summer is starting here is Arizona, so i decided since It's getting to hot to comfortably ride all day on the weekends, that it's time to start "Phase 2" of my HyperKromo project.

Phase 1: Is cosmetic changes to the bike. Including body work color, tail chop, seat, replacing the headlight, replacing the rear turnsignals, kickstand, etc.

Phase 2: Is performance changes to the bike. I'll be turbocharging the bike with Aerocharger 53 Series and custom exhaust.

More info: http://www.duccutters.com/BillJohnson-HyperKromo.tpl

DucCutters · #2 05-27-2009, 17:49

Step 1:

I got a Aerocharger 53 Series turbocharger mock-up.
http://www.Aerocharger.com/

I also acquired a stock catalytic converter and stock air box from a donor bike. I got the donor parts so I don't have to stripe my bike down for an extended amount of time...

I'll starting by building a jeg to emulate the way the stock catalytic converter connects to the header pipes and the case. My goal is to replace the CAT with the Aerocharger.

DucCutters · #3 05-27-2009, 17:55

Step 2:
I need to build a new steel air box. I'd like the air box to be a little smaller then stock, but keep the same mounting points. I hope to use the stock velocity stack gaskets too.

The air intake will be on the lower left corner. close to the vertical head. Blow-off value isn't need with the Aerocharger, so it should be pretty much a straight forward design.

DucCutters · #4 06-01-2009, 21:30

I choose to mount the turbocharger in the location of the stock Catalytic converter. This will make for a minimal amount of exhaust plubing to be fabicated and very clean installation.

My plan was for the turbo bracket/intake pipes to be a direct replacement for the CAT only. Unfortunitly it wasn't possible. It was about 3/4" off. So the lower horizontal head pipe will need to be modified. I have some U-Bends on order now.

More photos:
http://www.duccutters.com/BillJohnson-HyperKromo.tpl

DucCutters · #5 06-08-2009, 21:16

Exhaust intake complete and turbo mounted. I need another U-bend to complete the exhaust output pipe. The steel portion of the air-tube is complete except for welding and the Samco silicone hose has been order. I'll be using the stock mid pipe with the flapper valve removed. I'll also be using the stock slip-ons (cored to reduce back pressure).

The air-tube path (blue=Steel red=Silicone Hose).

DucCutters · #6 06-22-2009, 17:59

I didn't have enough material together to do anything productive last weekend.

The exhaust intake pipe, output pipe and mid pipe are all complete. The steel portion of the air-tube is also complete. Waiting for the Samco silicone hose for the air-tube. I'll going to wait till the end of the project to core the stock slip-ons. I mounted the 1098R kickstand and got it ready to be welded. Once the bike is up and running, I'll send the pipes and air box out to be ceramic coated.

I'll start laying out the steel air box next.

More Pix:
http://www.duccutters.com/BillJohnson-HyperKromo2.tpl

DucCutters · #7 06-30-2009, 21:42

Did a detail inspection of the stock air-box and how everything arounds it fix's or attaches. Looks likt the coils attached to the air box, so i'll need to simulate that too. I then cut my spare air-box into to see how the inside was structured.

After reviewing all my notes and sketching out a rough design, I built a 1:1 scale 3D mock up of the air-box out of foam core. Once I satified the mock up with fit. I'll take it's meausrements and draw out the design in 2D and have all the parts water-jet cut out of thin plate steel.

Talked with RapidBike about the electrons, just waiting for a price. I have a custom boost gauge from "Speed Hut" on order and I'm still waiting for the Samco tubing to get here.

Clayman · #8 07-03-2009, 11:13

Hows it going? you got have this beast out on the roads before summer is over, but I guess its not as short in Arizona as in Sweden :-)

Bloody good work, I look forward to the final result.

DucCutters · #9 07-06-2009, 19:06

I finilized the size and shape of the air-box [(445cc + 220cc) > 539cc]. I send out the artwork to the water-jet cutter this morning. I already have an order placed for a set of 51mm velocity stacks.

I'm on vacation 7/10 - 7/20, probably won't work on the project during that time (anniversary trip). I hope to have most of the parts in to make some major advances that next weekend!

DucCutters · #10 07-06-2009, 19:24

Quote:

Originally Posted by Clayman

Hows it going? you got have this beast out on the roads before summer is over, but I guess its not as short in Arizona as in Sweden :-)

Bloody good work, I look forward to the final result.

Summer riding sucks in Arizona! :flame:

The daytime high is above 110°F (44°C), 9 or 10 on the UV index and 15% Humidity. The asphalt temperature is around 150°F (65°C), so you don't want to set in traffic!

Summer here last for about four months (June, July, Aug, Sept). I'd move except the other eight months of 70°F (21°C) and very minimal rain makes up for it.

Arizona OK'ay. Technical I could ride over 320 days out of the year without to much discomfort.

I should have the project done by the end of August (if all the part vendors come through on time). Which will give me a month to get it tuned before the winter riding season starts. I really don't want to spend to much time tuning everything in till the weather changes in October.