Thursday 27 November 2014

KAWASAKI ZZRT1100 DAFFY F27 #6


Well. What a crazy couple of days....

Monday 24th consisted of putting the steering back together ready for towing to a friends the following night.


A bit of a wild ride with me sat in the drivers seat when dad towed at what seemed like 10000mph on country roads in the pitch black, it must have been -100 (no exaggeration) (honest). id say the car was more of a sled bouncing around the road with the quick rack not helping matters. never the less, this is part of the fun. 

The paddle shift and quick release modification to the Sierra steering column had us scratching our heads for a while... not sure on the best route forward we looked back to fords basic assembly and realised whoever manufactured the paddle shift assembly perfectly copied the ford design to use all the internal bushes washers and bearings, this realisation took more cups of tea and time than it should have! 


pushing on we drilled the quick release assembly to pin into the column to keep alignment when welding 



filled with confidence on how this was going we pressed on assembling and with the help of an air hacksaw to get rid of the no longer needed threaded section of the column we TIG welded the front face of the quick release adaptor then plug welded the pin into both the adaptor and the column 


End result couldn't have been better, paddles in the perfect position and a wheel that comes off, although, the engineering gods were on our side as after a long night at work and a wild ride to a friends we had overlooked steering wheel alignment, just happens its perfectly straight, not sure how that happened but it is. so happy days! (no one likes a steering wheel thats not straight) make sure you line yours up properly as this was a fluke this time! 


oh not to add a new addition for the car :D we love caterham seats! 


keep posted! 

Saturday 22 November 2014

KAWASAKI ZZRT1100 DAFFY F27 #5

F27 double up on some top chassis rails on the left hand side of the top photo, the diagonal box section fits great with a car engine but it directly in the way of the exhaust and in our case where the turbo is going to fit, so it has to go - we will put the strength back into the chassis by using an engine brace which will also act as the back mounts for the engine and support the turbo. it took about an hour to cut out the chassis rails as they were stitch welded underneath. 




A few hammer blows later and a lot of "get out you B#sta#d we have a lovely space to drop our turbo into.




Now we have some space to work around the turbo we will need to remove the passenger side alloy panel from the car and i think cut out some 1" box section from where the turbo will fit and replace it with something smaller and removable. Now we can start machining the steering column to fit the paddle shift and quick release boss. keep posted! 

Sunday 16 November 2014

KAWASAKI ZZRT1100 DAFFY F27 #4

Today got goofy back up and running, the machining to the prop adaptor worked a treat, lets hope it doesn't come loose again! cars are now swapped over in the shed.

Next job cut out some box section from the chassis to allow the engine to move further over in the engine bay, then onto the steering and paddle shift.





Saturday 15 November 2014

KAWASAKI ZZRT1100 DAFFY F27 #3

First things first, 

First job on the cards is to get the prop adaptor back on our zzr1100 F27, I've machined it down 1.2mm for the locking washer to actually engage with the spines on the output shaft, something its never really done! I done this to the new one as its going to be put under a lot more force when turbo'd than the standard zzr1100. Once the NA F27 is on the other side of the shed its time to crack on with the turbo build, exciting times.



Just cause we can,

This year we fancied going for paddle shift, aswell as the normal gear linkage, following a mistake from cable tec last year we have ended up with two series 4 gear linkage cables that take female m6 rod ends. We have bought a paddle shift system and it doesn't fit! and a quick release boss which also doesn't fit - nothings ever "off the shelf" the steering column will need turned and welded for the steering boss and the paddle shift housing will need cut and welded to bring it closer to the wheel.

Sunday 9 November 2014

KAWASAKI ZZRT1100 DAFFY F27 #2

Its a good time to let everyone know where we are currently with the build.

The crossflow engines out, the cars actually looking a lot worse than the second picture now, and will look even worst when the side panel comes off to get some room to work around the turbo, mocking up the stupidly big intercooler and some turbo bits, I will go into turbo details in the coming updates.

First job on the list is quick release steering wheel and set up paddle shift, so it can roll about again. more in-depth details shortly!

pictures speak louder than words:























KAWASAKI ZZRT1100 DAFFY F27 #1

Firstly, can I just say in advance apologies  for the grammar and spelling mistakes you will see throughout this blog, it will be done on cold winter nights in bed after pissed off nights down the shed, most of the posts will no doubt be done intoxicated! And I just realised it doesn't have spell check!  

I'm doing this as I wish I did last year for fellow builders, friends, kit car entusiasts, readers, drivers, people who havnt started, people who have finished, key board warriors and my self. I'm not saying what's in the blog will be right, I think the mear nature of a seven won't allow for anything to be "correct" for everyone's point of view. However, personally using and following blogs has helped me build my knowledge on a vast amount of areas kit car related and not so if this one does the same, and because of this more people are willing to give turbo'in bike engines a try from there shed, then happy days! This is going to be a big learning curve for me also never turbo'sing anything previously! 

Who knows I might add pointless hours to the project typing away on here and nobody might read it! 

Lets start with some background!

One cold, misty November night about 6 years ago I was helping out teacher, now very good friend, Geoff Wallman build his CBR1000 blow through carb turbo locost. We had reached the stage in the "night" (a common theme I will learn) where it was ready for a blast round the school yard. Never being in one of these before, I had no idea what to expect. I knew dad was passing from work so asked him to call by, this might be my chance to get him into the idea of a 7. This style of car was beginning to and admiddingly still is the only thing that impresses me, something someone has physically built with there knowledge and hands impresses me greatly and I now love taking ideas from other people and adopting them in our builds. Soo.. Dad arrives at school and he watches me scream and shout f#cking hell this is the fastest thing I've ever been in. Geoff was probably doing about 0-20mph just coming on boost at about 3k Rpm! (Like I said never been in a seven befor) the noise was like being in a tornado as the garret T25 spooled and dumped on, off throttle to feed the little Honda power plant. Dad was up next and much the same! We both went home thinking we have to have one. It's probably all I spoke about for a good few weeks. The adrenaline these cars produce is crazy! This is were the addiction began.....

A year passed of trying to convice dad to buy a road registered rolling chassis and put a turbo bike engine in. Two points here. 1. Why at 17 just passed my test did I think any insurer would cover me on a 200bhp bike engine turbo!? 2.why at 17 did I think I had any money to carry out such a project!?

Anyways, a rolling chassis that had blown up a crossflow on a track day I had spotted months before hand on eBay, rightly turned down by dad, turned up again, this time with a working engine. me and dad had bought a nakered trailer with 4 (more like 1) wheel and set out to have a look. The first time we seen it, it had to be ours, people who know me and Tony Gray, this car is the famous Goofy! It adapted it's name purely due to it's Registation plate ending GFY, something that stuck from day one. 

We arrived home in style, the trailer AND kit car where on the back of a AA truck as the one working wheel shot off into a field leaving the other 3 to fall apart mid journey. Let's get it right, when we got goofy it was a shed, about the same as the shed we build the cars in! Engine number 1 filled a coke bottle with oil on every journey, we built a race spec crossflow, and moved over to bike engine last year, with huge help for Geoff and also John Richardson, both very knowledgable chaps in thier fields. 

Last years bike engine install was when I wish I done a blog as I learnt a lot about engineering and would have been good to pass this on, something I'm always willing todo.

Over the last 4 years me and my old man have been tinkering on in the shed and have built up a "good" understanding for engineering and also how to take shouting at each other when something doesn't fit! 

Anyways, we have just bought the turbos, inter cooler pipe work plenum and more yesterday so keep posted for updates! Enjoy....