Fitting a turbo to a Suzuki motorcycle | Turbo Bandit Project part 4

So here is the new Suzuki Bandit 1200 Project bike. The plan is to turbo the motorcycle, it's going to need an engine rebuild and some TIG welding and will be a learning process for Shroom.
This week Shroom Gets the turbo manifold finished and mounts the turbo, plus he needs your help with the exhaust fabrication.
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[@KevsShed]

There's nothing to fear regarding the balance of the turbo Ian, the balancing is between the exhaust turbine and the impeller, as you aren't removing either of those from the core then the balance won't be affected buddy, hope that you managed it in the end! 👍

[@Classicmotorbikes]

Thanks for the info Kev, I’ve done some research and the core should be pressed into the exhaust housing 😱 as I don’t have a press I’m worried about not getting it back in square and causing something to bind.

[@philippemarcelgrohmann1225]

I was waiting for that! Keep doing this!!! 🤗

[@Classicmotorbikes]

I’ll keep doing this 👍 I can’t wait to ride it for the first time but I’m also enjoying learning how to build it as well 😎

[@BorisKarloff66]

Great video mate, I liked your jig, great idea, it saved tacking it up in the frame. As for what exhaust, i would go with the full exhaust system, like others have said a sleeper turbo build Keep up the great work

[@Classicmotorbikes]

Hey Adam, the jig isn’t perfect but so much easier than working straight off the bike, I do like the idea of keeping it as a bit of a sleeper but someone suggested making the exhaust modular so I can change it easily, I’ve got a plan and fingers crossed it will work 😎

[@larrybarnes3920]

There's nothing to fear in reassembly. You got it apart you can get it together again. 👍

[@Classicmotorbikes]

Thanks for the vote of confidence Larry. I might give it a go but get it checked over afterwards

[@tzrdan]

Great to see more progress on this one Ian! Slash cut exhaust all the way!!

[@Classicmotorbikes]

Hey Dan hope you are well, it’s good to get some progress on video. I’ve got a feeling I’ll need to get some more exhaust flanges so I can have one for every design 🙈

[@AdamGTS350]

Good to see some progress mate. I've recently built a CB900F with a garrett gt2560r turbo hanging off a shorty manifold similar to yours. For the dump pipe I used part of a 90 degree bend cut in such a way that the outlet is a tear drop shape about 200mm out from the turbo outlet flange. Its loud, but not as loud as say a open pipe Harley as the turbo has a small amount of muffling effect. Coolest part is the flames it belches on engine run down/deceleration in gear, my right riding boot does get pretty warm on a decent ride tho...

[@Classicmotorbikes]

Thanks Adam, I do like the tear drop idea but like you say I was a little worried about my foot getting warm! Are you using the standard CB900F engine? What RPM does it make boost with gt2560r? Have you had it on a dyno? Ian

[@67Screwy]

Great job,the only thing you need to worry about the turbo is taking off the turbine blades,they are a balanced assembly,everything else just simply bolts back together,as you took it apart,simples! Also don’t use a metal gasket on the turbo to manifold join,use paste instead as the metal ones break up and go through the blades and bugger the turbo up! Great work, I built a turbobusa 5 yrs ago and two years ago got involved with Bigcc racing in Wokingham and now have fully built the motor and got a Bigcc turbo kit, once you start on the boosted road there ain’t no going back! Your want more boost within a year trust me😄

[@Classicmotorbikes]

Thanks for the info 67Screwy 😎 my plan is to have this as my first experience into turbo motorcycles, when I've had my fun I plan on trying to improve the kit I've made and get some more power through different ways. I've got a feeling this will make the "It's Bandit o'clock" bike a bit slow!

[@Almightyrastus]

Good to see this series back again. With regards to the exhaust, I would definitely build a full system as one option and look at doing it with as much modularity as possible with the options to swap out bits and pieces as you want/need. That way you can have sommat a bit more sensible or straight pipe it right out the back. Then use the other flange to make up sommat real nasty with a short pipe. Take a look at the Fasterproms channel and look at what they have done on the Katertot exhaust (Turbo Honda K-swapped Smart Car), the exhaust tips on that look spot on.

[@Classicmotorbikes]

That’s a great idea about making it modular 👍 I think I could do a couple of different setup on one down pipe that way 👌love the Katertot Build what a crazy thing, I’ve got to agree the exhaust does look good on that

[@MrPsiclone666]

good info on maximum suzuki forums on turbo setups the yanks love them

[@Classicmotorbikes]

Thanks for the recommendation, I’ll check it out 👍

[@SAM-zt2uy]

Interesting to see the re clocking of the turbo, many moons ago I was going to swap to a bigger turbo on my volvo but the clocking kinda put me off, I think a few turbo bikes use the volvo turbo because it’s fairly small for quicker spooling and can about survive on 15psi which is mega fun in a 1.5 ton brick

[@Classicmotorbikes]

Hey Sam, thanks for the comment. I was a bit unsure of clocking the turbo as well but seen that most fitted to a bike needed it. The toughest thing so far has been trying to remove the dowl from the compressor side, that and removing the core from the exhaust side!

[@bostonbikebits6539]

Go Shroom!! Been looking forward to this.

[@Classicmotorbikes]

Hey Dave, hope you are well, I’m enjoying the Junkyard Dog project over on the website 😎

[@jimmycav369]

Great idea using wood as a template for all your exhaust positions

[@jimciancio9005]

Don't want to be raining here on anyone's turbo parades here, but before you go much further into your project and figure out the harder way. The turbo, especially the non sealed journal bushing type can not be mounted lower or inline with the engines oil. Otherwise being the lowest point of your oil level, the oil will be inside the turbo drain pipe and continuously pushing oil out the journal bushings into both the exhaust and intake sides of the turbo shaft. This is why they are usually mounted on the upper sides of a engine or on top, in front, but above the internal oil level of the engines oil capacity. Also if these types of turbos cannot drain off the excessive oil quickly enough AKA because the oil is as high or lower than the internal static oil level, even while running the thing is going to be puking out oil into the exhaust and intake system. A healthy rule of thumb is no less than 3 inches above the oil capacity of the engine. Unless you are planning on using some sort of remote oiling system that sits below the engines oil hight somehow? At this height where you are planning on mounting it, it will be a very hard learning curve, which I'd really not like to see someone go through. It costs valuable time and money. Unfortunately Unless you are planning on spending stupid money on a custom made ceramic ball bearing sealed turbo? Which I think the same basic rules apply for as the oiling drain back to the sump needs to be slightly higher than the oil capacity so when it's not being used all your engines oil or at least to the hight of your turbo will be draining past the journal bushings as it sits there loading up both ends of your turbo. That's particularly the main reason for this main rule of thumb. Turbos unlike say a supercharger, do not posses any type of springed rubber/viton lip seals. They usually rely on the metal to metal fitment and some specialty designed almost cupped washers or rifling basic of the journal bushings that helps redirect the excess oil which has made it almost to the outer ends of the cartridge and shaft, which redirects this oil back into return holes inside the cartridge, so It ends up flowing downstream and back away from the turbo and into the sump of the engine or catch can if you are using a remote oiling system? The drains on about 90+% if not all should be done so gravity is removing the excess oil from the turbo cartridges. Any sort of back-pressure or ie; oil level built up within your drain tube is going to have no other options, but to push your oil out of the bushings and shaft ends. This will result in a nonstop fog machine action, and depending upon how worn the turbo is? Ie; used? This effect will be even much more prevalent than say something tighter or rebuilt, no matter what though it will happen and especially if you attempt to utilize your dry turbo as a "draw-through" the creation of a deep vacuum upon any sorty of throttle blade closure with increase the amount of vacuum on your compressor side and being a journal shaft design is going to literally wanting to suck the oil out the the non sealed shaft and filling the compressor housing full of oil especially if it's below oil level. Another issue is that if you're planning like so many do on KZbin and going with the draw-through style? Your journal shaft turbo is not long for the world. Buick found all this out when they were designing their first turbo engines before electronic fuel injection. They had to have Garrett build them a specialized turbo for use in the draw-through system. Because of the prior mentioned above. Unlike superchargers, a turbocharger was never designed nor intended to handle any or much negative pressures on the compressor side. The oiling system was just one of many hurdles that Garrett had to try and overcome with the custom designed new turbo. But even though they were able to mostly work out the oil and vacuum issues? This also came at a price that shortened the lifespans of the new designs before they would start to leak internally. However it's your project, and you do you Sir......I'm just trying to control the crash your about to have. Good luck my man. 😉

[@multtube]

😎 Man excellent video as always.. I think Short exauts to the foot rest or full system will make beter looks.. Awesome cooking...😁😁😁

[@Classicmotorbikes]

Hey Jay glad you enjoyed it, I think the 2 exhausts you suggested are my favourite so far 👍

[@grahamhider3754]

45 slash cut. Nice work well done 👍

[@Classicmotorbikes]

Thanks Graham, think the 45 slash cut would be nice and simple to do 👍

[@tomdickharryjane]

@@Classicmotorbikes To start. Get it running first.

[@reggiebacci]

Full exhaust mate and I'd follow the original routing as closely as you can. In my experience Suzuki put stuff in places for reasons you don't always appreciate until after you've cocked it up. Don't ask me how I know.

[@Classicmotorbikes]

Thanks Reggie, don’t worry I won’t ask 😮 I do like the idea of a full system

[@deighmo]

I don't know how you got your head around all the angles for the headers. Excellent job mate. I reckon a slash cut exhaust just behind the footrest to stop it looking to front heavy. Look forward to the next one, thanks.

[@Classicmotorbikes]

It did take some time and head scratching, I wanted to show off the fabrication more but sometimes I’d be in the garage for 2 hours any they didn’t look any different 🙈 I like the idea of a turn out just behind a below the foot pegs 👍

[@StudentLife7666]

Cool video))

[@leebrookes7611]

Looks fookin awsome mate want mine turboed so bad slash cut looks mental mate

[@Classicmotorbikes]

Thanks Lee, I’ve been wanting one for years decided it was time to try and make my own setup, think a slash cut could work 👍

[@CLMUZAK5775]

Thanks super in depth!

[@remfanuk1970]

came across your channel...i am doing a bandit special and liking the idea of a turbo too...good work keep it up...sub'd now.

[@Classicmotorbikes]

Thanks for the Sub Remfanuk1970. how are you getting on with your project?

[@hassejohansson3617]

Good work mate looks cool.

[@Classicmotorbikes]

Thank you for the kind words

[@8713Thomas]

Definitely have a pipe coming out just behind the foot pegs!

[@Classicmotorbikes]

Hey Tom, I really like this idea, someone suggested making it modular so it’s easy to change and I think I’ve come up with a plan that could work well.

[@8713Thomas]

@@Classicmotorbikes excellent! I love it when a plan comes together! I can’t wait to see it on KZbin. Great work again.

[@Classicmotorbikes]

Cheers Tom 😎

[@TheMotospot26]

I’m all for a stealth look, so a full exhaust, yes a turbo isn’t exactly stealth but if it doesn’t scream at you people aren’t going to think twice

[@Classicmotorbikes]

I like your thinking Andy, might make life easier when it’s due an MOT as well.

[@martin.5336]

Full exhaust system keep the standard look.

[@Classicmotorbikes]

I’ve got a feeling I’ll go for a full system, try and go for that sleeper look, well as much I can with a turbo behind the front wheel!

[@tomdickharryjane]

Finished part 4. Still hanging on, what did you find with cylinder 4 carburetor preventing it from running well in part 2???? You're killin' me, smalls! For the exhaust, I say keep it simple. Go with a 45 out the turbo to start. Save the second flange until you get it running. Then, you can redesign if sound levels require it.

[@Classicmotorbikes]

Hi Tomdickjaneharry I replied to your other comment about the carbs, turns out the butterfly was completely closed on no4, adjusted it like you would when balancing the carbs and now it runs great 👍 I’ve got a plan together for the exhaust with suggestions from the comments, I’m going to try and make something modular, should be interesting!

[@tomdickharryjane]

@@Classicmotorbikes Cool, thanks. Sorry for asking again when aswered. I am curious then how did you notice on editing? I did not see anything wrong when I watched the video. Looking forward to the rest of the videos!

[@Classicmotorbikes]

tomdickharryjane when editing the video I have a clip that didn’t end up in the video of me moving the carbs and you could see a bit of light behind the other butterfly’s on the other carbs but not no4

[@tomdickharryjane]

@@Classicmotorbikes Makes sense, thanks.

[@russellhale7694]

Exhaust under the engine and exit at the footrest would look good to me.

[@Classicmotorbikes]

I like the idea, I think this will be my preferred style 👍

[@richardwoodhouse8397]

Slash 😮

[@ideey1]

Full exhaust system..

[@Classicmotorbikes]

I like the idea of a full system for a for MOT time, what sort of end can would you use?

[@BanditK]

Can I suggest a full delkevic exhaust system

[@KamdinRFrost]

What would you charge me to build me a set of turbo headers??? Bandit 12 aswell mk1

[@Kurbits]

Make a full system or at least past the footrest.

[@Classicmotorbikes]

I think I’m going on make something modular as someone suggested, I’ve got a plan to get one behind the footrest and a full system 👍

[@joshsutcliffe6099]

I need to find a manifold for my 2000 bandit 1200s

[@martinj9251]

Did you back purge the headers when welding, Nice weilding to be fair

[@mrbanditoh4436]

@Classicmotorbikes did you install the mk2 1200 3 piston front brakes? was there anything you had to do or did they just bolt right up? thanks!!

[@mellfacioli8898]

Boa noite meu amigo belo projeto eu tbm tenho uma Bandit 1200n montei um kit turbo nela porém estou com dificuldade na entrada e retorno do olho vc pode me ajudar dês de ja muito obrigado

[@joshsutcliffe6099]

Mine is hitting the top brace. I can't get the two center pipes to seal up because of it

[@deanknight3396]

Hi Every time I see a turbo bandit it has the real short open header is that important? So for instance I hand this bandit turbo. With a longer pipe could I fit a exhaust can up the tail end or is this a no no I’m very curious???

[@markstewart7888]

Full system, keep it sleeperish lol

[@Classicmotorbikes]

I am a fan of a sleeper, not sure how much of a sleeper it will be with a turbo sat behind the front wheel 😂 but I think that’s the look I’ll go for.

[@JustinNoury]

Where can I get the turbo and exhaust mount? Also can I do this on a 2009 1250s?

[@austin_94gt18]

Im sure there are others watching like me that would pay for a set of custom headers if you ever decided to build them for people to purchase.

[@JustRockin]

Hey dude, great work. You seem very nice too! Any updates feasible yet? 🙂

[@Classicmotorbikes]

Hey Buddy, Thanks for the kind words, I’m just making the next video as I type, should be here soon!

[@paulbudford]

Build something that's not going to burn your foot. 😉

[@Classicmotorbikes]

Good shout Paul 😛

[@Dominantliveband903]

Please I have issues with my s1250 Bandit engine getting locked while trying to start, so I open the side cover trying to turn the engine opposite side so still get lock after two turns. Please can you help me to know what could possibly be the cause?

[@richardwoodhouse8397]

Starter clutch

[@jpich85]

What turbo are you using mate? The td04 seem like the one but not sure which version, are you planning on external wastegate?

[@Classicmotorbikes]

Hey buddy, I wasn't sure about what model to use, I think I've got the smallest one a 13t, but from the research I've done people have used most of the different models on a bandit 1200. This turbo will just for me to try out having a turbo bike, my plan is to upgrade and learn more of the science so I can make a better turbo system. For this setup I won't be using an external wastegate, but I might look at it on a future kit.

[@jpich85]

@@Classicmotorbikes thanks mate, I'm hoping to start my project too next year and have been doing a load of research, are you putting busa pistons in this build, I don't think there definitely needed for boost below 8psi but I was advised to do that upgrade as the engine won't last too long on the stock pistons, how are you planning on controlling the boost? I haven't found out how to mod internal wastegates yet but obviously external ones come with different rate springs, thanks for your reply mate

[@Classicmotorbikes]

Yeah my plan is to use Busa pistons from the start so if I decide to turn up the boost I don’t have to worry. I think you can get different actuators for the internal wastegate so you can alter the boost that way without a external one, but I need to look into it more. I’ve just seen your message Instagram, will speak to you more on there 👍

[@jpich85]

@@Classicmotorbikes nice one mate 👍

[@architude]

I'm not subbed and neither am I looking for a Part 05 to this pet of of yours, now at two years old upload date, but straight out 45deg with a slash cut brother. Boo Yah.

[@pantysnifer927]

When I can't gead my "head(er) in a "whole" easily I also wiggel a little bit...

[@Classicmotorbikes]

Good to know.... I think! 😮

[@shaunsk8ordie]

Teardrop

[@Classicmotorbikes]

Thanks for the input Bronson, I hope I get it right first go as I don’t have many 90 degree bends

[@gualbertoserrano5205]

greetings, I find it impressive for your work, congratulations. how can I contact you for future projects,

[@user-ui4jf4gi3i]

You good man Good luak