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Discussion Starter #1
Hey guys its time to start this build i think and this thread will hopefully be a good center for discussion on it and a cesspool of ideas that will spawn one hell of a BRP i hope. sorry to all you droolers out there this build will be as i go and acquire parts and ideas along the way.

First things first the patient will be an 05' xr650r i picked up converted and plated 75% decorked and barely enough wiring to call it legal.




Now the plan....

USD forks conversion

RAD MFG hubs and excel wheels to replace the talons. red hubs and spoke nipples on black excels 5" in the rear (I will be selling the talon/excel combo 1000$ look for FS ad)

RE-wound stock stator for 200ish watts ran through a mosfet reg/rec for DC power and BATT (reasons as follows)

HID lighting from BUELL xb12r projectors in a custom made headlight housing i will be fabbing. Im thinking this will end up looking somethink like a transformer from the front lol

GT15 TURBO looking for tripple digits on the ponies for this which will require some engine mods to be determined exactly what later. most likely carrillo rod and port polish with hot cams 1 i think as the turbo will make up for the top end.

FUEL INJECTION via microsquirt but that will be wayyyyy down the road and most likely on the second variation of turbo kit. besides they are out of stock till at least aug.





IT starts I have already procured the USD crf450r forks and tag triples w/ conversion bearing to make the triples plug and play to the xrr head.


I have also procured the gt1544 to start fabing for that little beauty. I think i will be installing it towards the rear of the bike right at the beginning of the muffler as there is enough room and moves the weight farther back as the BRP is a bit nose heavy as it is.



my first thoughts were to mount it as close to the head as possible for ease but the turbo i have still runs the gt12 inlet flange and not the t2 flange which would be perfect to fab a manifold for 1.5" runners right down its throat next to the left radiator. but alas that may end up in BRP-T 2.0 :anim_peep:



So as you can see nothing is started yet she still runs strong the bike has a presumable 3000ish miles on her and looks like it very pristine waiting to be modded. For starters ill be doing the USD fork conversion while im doing more testing for the turbo cooling system and getting the rest of my required parts and pieces.

So any ideas or suggestions shoot em out lets make this beast scream :arsenal


LOOKING FOR!!!! PM me on any of this!

any stock vehicle intercooler that the pressure runners are 7-9" long and no more than 2" thick that i can cut down and make an intercooler for.

front axle w/ nut CRF450 06' or any year that will fit. hell if you have a front 21" wheel with it even better at the right price.

gt12 turbo inlet flanges and exit flanges.... if not ill just make em itll give me an excuse to use the plasma cutter more :thumbup:

and like i said any suggestions along the way.

z
 

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Thats gonna be insane! Hope the next thread you start when this bike is done isnt about how this brp ripped both of your arms off!

Gonna need videos when its done too
 

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:thumbup:
 

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Discussion Starter #4
Thanks guys ya it should be fun once done. :thumbup:

Ill be using a few of the inovations tommy_j used in his turbo 950SM seen in this thread.

http://www.advrider.com/forums/showthread.php?t=656921&highlight=turbo+install

and a lot of this will only be for revision 1.0 on this for the carb setup. Im going to atempt to use the stock carb for starters but we will see how far that goes

things like the pito tube and on demand valve (2stroke reeds) should make it very streetable. I will however be using an intercooler as in the end i dont want to add too much weight after all is said and done.



For progress i havnt started turning wrenchs yet but the plan is there this week. im hoping my wheels sell though itll let me order the new wheelset sooner.

But for now the plan is to test a redesigned cooling system to allow for the intercooler to replace the left radiator. My plan is to add 1 or 2 spal 4" fan(s) running off a spal 195f relay kit making it self regulating on the right radiator. I will be blocking off the crossover lines for the dual radiator setup for now and running the fan off a switch for testing. If it works out in this stockish form i will go ahead and order one of the e-bay aluminum radiator kits, the china bay ones at 200$ for the set to help increase cooling ability with just one radiator. we shall see how this turns out before i continue designing the turbo system placment and routing.


I need to see if i can run the fan off AC power for now or ill end up having to change that to DC sooner rather than later to allow the testing to commense.

z
 

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Sounds excellent. Subscribed!:thumbup:
A bit off topic, but do you mind me asking how much you picked up the bike for?
 

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I'm watching this thread for sure, I don't think I would ever do this to my XR, but watching yours will be a blast for sure. I do have one suggestion, if this is going to be your primary build thread, get a better camera than your cell phone. The pictures do not and will not give justice to the materials and build itself. I would film some of the steps and big ticket items, that would be fun for everyone to follow and be a part of. Good luck on this project, and I can't wait to see the finish product.
 

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Discussion Starter #8
Sounds excellent. Subscribed!:thumbup:
A bit off topic, but do you mind me asking how much you picked up the bike for?
3500 with dirt setup as well. for the condition year and dual sport setup it was worth it. although now that im changing half the suspension I can only hope some one wants to pick up the front wheel so i can replace it with the crf one and i can dual sport some fireroads after shes got the bugs worked out.

I'm watching this thread for sure, I don't think I would ever do this to my XR, but watching yours will be a blast for sure. I do have one suggestion, if this is going to be your primary build thread, get a better camera than your cell phone. The pictures do not and will not give justice to the materials and build itself. I would film some of the steps and big ticket items, that would be fun for everyone to follow and be a part of. Good luck on this project, and I can't wait to see the finish product.

Dont worry tdogmason i have every intention of taking as many pics as i can with my actual camera, i just wanted to start this as iv been putting it off but wanted to get it out there so maybe i can get some more ideas along the way. as well as getting it out there im looking for certain things if anyone has em laying around and wants to help out.

although iv kinda been dragging feet on this as i still have my yz450 and theres riding to be done!! lol But i think that its going to sell soon and itll really boost funds toward this build and ill want a sumo back on the street at that point.

z
 

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nice! i boosted my 250x and that fun while it lasted! cant wait to see another pressurized tard! :clap:
what happened to your boosted wr250x?
 

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Discussion Starter #14
Well im sure some think iv already fallen off the grid on this but im here just dragging my feet a bit between work and personal commitments. BUT i have finally ordered a few parts so the project can continue.

first off is the Shindengen FH012AA mosfet reg/rec upgrade to go from current shunt type reg/rec's that draw battery power when not being powered and also degrade over time because of the constant grounding out of the power to regulate when your not using the power. in eccence a very inefficient setup but ok for most of our style setups, just not for mine as im looking for max electrical power and minimal loss. it can be read about in the following link.

http://roadstercycle.com/Shindengen FH012AA Regulator upgrade kit.htm

And i also ordered my 16g magnet wire to rewire the stator in hopefully 3-phase A/C to get max current from the relatively small compared to other street bikes stator on the XRR.

As well as the 1/2" plate i will be making the turbo flanges from.

Next on the list will be tracking down the right sized SS pipe to go from stock header to the turbo. and then the aluminum piping as well.

However as long as the potential buyer for my YZ450 comes through ill be going ahead and getting the RAD wheels on order as well, which has been a major slow down honestly in this project as i really want to get the USD fork conversion completed as one of the first things.

But research and progress continues.

z
 

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Discussion Starter #16
If you're going with showa forks then try and grab 05+
reason? and the ones i have are 06 not that id resell and get others if i didnt have 05+ lol.

z
 

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By 05, all of the standard showa TC, that I know of, were using the larger redesigned base valves. Most also have the same caliper spacing now as they did then. If you didn't already have the forks, you may as well aim to buy the better years.
 

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Discussion Starter #18
By 05, all of the standard showa TC, that I know of, were using the larger redesigned base valves. Most also have the same caliper spacing now as they did then. If you didn't already have the forks, you may as well aim to buy the better years.
Thanks for looking out. But i feel most setups can be setup aftermarket to suit my needs even if i didnt have the newer year forks already. But im still debating on when to get the suspension redone. now or later?..... Might give F.B.I. a call and see what itll cost and turn around time and go from there. Everyone raves about after getting their suspension redone for sum duty and if im going to rock this bad boy for a while i want that feel too.

z
 

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Discussion Starter #19
So this is the basic Y-configuration 3-phase A/C stator rewire im going to try as opposed to the standard 1-phase that most do. Supposedly im going to get more current and less voltage out of it, but im starting to wonder if the 16g wire is going to be too big now with only having 3 poles per phase which will net not enough voltage. Any electrical geniuses out there want to chime in before i find out for myself in a week or so?

z

 

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update? :anim_peep:
 
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