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  • FZR-R3 Turbo build

    Still in the initial stages of building the turbo kit but coming along nicely.

    Went through 3 different configurations until I found one that I'm happy with. Just waiting on some final items to arrive to complete the turbo kit fit out. The whole idea for me is to use as little piping as possible and recycle the water exiting the IC - this will help minimize waterlines being routed which will bring cost down as well. I'll be converting the rectifier to waterless and relocating it from near the exhaust. All of this will be explained in more detail in upcoming posts when I'm putting everything is ready.

    Let me know what you guys think about it so far [emoji41]

    Shoutout to Samay Arnaiz supplying me with the turbo [emoji482] & R Allen Carpenter for hooking me up with the care package! [emoji57][emoji16][emoji1363]

    NOTE: THE ENGINE IS JUST A CASE WITH A HEAD BOLTED ON TO USE FOR FITMENT PURPOSES ONLY.
    ALSO, THE SILICONE COUPLERS ARE FOR FITMENT PURPOSES ONLY - THIS KIT WILL USE 3 VIBRANT COUPLERS AND ONE FABRICATED PIPE.Click image for larger version

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    Last edited by R3_killa; 05-02-2022, 10:07 PM.
    2010 FZR - Turbo build loading...

    GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

  • #2
    Good luck a lot of time & work relocating. Using intercooler water will work. But fizzle likes it to dump if possible for most flow. Just a fyi
    2016 FZ, Custom turbo design, Borg Warner EFR 6758 W/V-band .85ar, Still dialing set up in...20lbs of boost, 9240 RPMs @ 94mph (in Alabama Heat with tools, fuel, full cooler, & 245Lb rider).
    Build Thread: http://greenhulk.net/showthread.php?t=292838

    Comment


    • #3
      Thanks - I'll keep that in mind.

      I plan on having the 2/3 IC exits feed the intake manifold and fuel rail (&#129323 then will dump directly out the hull from separate exits. I'm considering a pressure valve that opens at a specific pressure on the intake manifold exit to ensure the IC operates at optimal pressure but that's something to test when the time comes.

      The 3rd will be a 3/8 hose that feeds the turbo bearings then dump out the hull - this will be 3/8 right through.

      It's going to be an interesting build but always open to different opinions in making anything better once by theory, it make sense. [emoji482]

      Originally posted by mittens View Post
      Good luck a lot of time & work relocating. Using intercooler water will work. But fizzle likes it to dump if possible for most flow. Just a fyi
      2010 FZR - Turbo build loading...

      GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

      Comment


      • #4
        Looking good, cant wait to see the final product, I'm jealous Let us know what was the most difficult steps, thanks.
        09 FZR Stage 3

        Comment


        • #5
          Thanks man - Will surely be updating the post regularly [emoji1373]
          There are a few things that will need careful thinking but won't be much of an issue after assessing thoroughly. I am very meticulous when it come to my builds and presentation. I've had this build written down for some time now and time to bring it to life! [emoji41]

          Originally posted by badjoka View Post
          Looking good, cant wait to see the final product, I'm jealous Let us know what was the most difficult steps, thanks.
          2010 FZR - Turbo build loading...

          GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

          Comment


          • #6
            Looking awesome Tyson!
            Save money on your pwc performance parts! Use the discount code: greenhulk when completing the checkout process in the GREENHULK PWC Performance Store and save 10% off the listed price of MOST Riva Racing and ALL WORX Racing Products. We also offer Fizzle Racing, MaptunerX tuning bundle packages, and instant download tuning licenses at discounted prices.

            Shop now! www.greenhulkstore.com​​
            Contact us! [email protected]
            Like us on Facebook! www.facebook.com/GreenHulkPWCPerformanceStore

            Comment


            • #7
              Originally posted by Green Hulk View Post
              Looking awesome Tyson!
              Thanks Jerry! Just waiting for some parts to arrive at ShipSmartUS then gonna have them shipped next day air [emoji41][emoji57]
              2010 FZR - Turbo build loading...

              GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

              Comment


              • #8
                Looking good man. Its going to be one hell of a ski. I always worry about running lake water straight to the turbo, cold water could cause an issue on startup. My 2021 pump parts should be coming in soon and I will run a dedicated line to cool the turbo and dump the rectifier overboard.
                The line will go from strainer, to up-pipe, turbo cartridge, downpipe and out.
                2018 GP1800 Custom Turbo setup, HO cams, Supertech valvetrain, Fizzle Y1000, 3.5" thru hull exhaust. Tuned by Jesus @ Riva Racing

                Comment


                • #9
                  FZR-R3 Turbo build

                  Originally posted by Reaper9789 View Post
                  Looking good man. Its going to be one hell of a ski. I always worry about running lake water straight to the turbo, cold water could cause an issue on startup. My 2021 pump parts should be coming in soon and I will run a dedicated line to cool the turbo and dump the rectifier overboard.
                  The line will go from strainer, to up-pipe, turbo cartridge, downpipe and out.
                  I understand your concern and is something to consider however, water temps here in Cayman average between 79-84deg F all year round so the water being too cold isn't something I'm going to worry about [emoji28] Also have to take heat soak into consideration.

                  I've drawn out how my waterlines will be routed and will post that in the coming days for everyone to see and hopefully get some helpful feedback - I just want to put in on a more presentable format because it's just on a notepad at the moment.
                  2010 FZR - Turbo build loading...

                  GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

                  Comment


                  • #10
                    FZR-R3 Turbo build

                    Here's the layout of the waterline routing. I tried to make it as readable as possible minus the congestion.

                    The strainer will be 1/2ÔÇØ feeding 3/4ÔÇØ to intercooler. Intercooler will have two 1/2ÔÇØ exits - one feeding the fuel rail and flowing freely, the other feeding the intake manifold with pressure relief valve on the exit. The pressure relief valve should help keep the intercooler pressurized and only open when needed. This should keep intercooler temps down.

                    The nozzle will be 1/2ÔÇØ feeding oil cooler and engine block cooling plate.

                    The factory thru-hull will feed exhaust and engine block cooling plate and will also be 1/2ÔÇØ.

                    The intercooler will also be feeding the turbo bearings with 3/8ÔÇØ waterline and exit straight out the hull.

                    The exit at the top of the exhaust and exit in the cooling plate will feed the up-pipe > down-pipe.

                    The factory thermostat exit is deleted which is replaced with the Riva thermostat delete and will also have another exit under the intake manifold with thermostat from R&D.

                    Open to any suggestions/constructive criticism.

                    Click image for larger version

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                    Last edited by R3_killa; 05-15-2022, 06:51 AM.
                    2010 FZR - Turbo build loading...

                    GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

                    Comment


                    • #11
                      Here's some logged data when I was supercharged. Was running water-cooled compressor housing, Fizzle Y1000 with Z3 and waterline layout for the engine is pretty much the same. I'm only making necessary changes mainly to the intercooler system now that I'm going turbo, with higher compression (9.5:1) and 2.0L stroker kit (87mm x 84mm).

                      Low boost will be 15-18psi and high boost 25-27psi. With power expected to increase and extra heat coming from the turbo setup (will have a turbo blanket installed) this should create more heat soak. Venting the hull properly is my next task to minimize heat soak.

                      It's good to revert back to data previously recorded as a baseline.

                      Click image for larger version

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                      2010 FZR - Turbo build loading...

                      GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

                      Comment


                      • #12
                        Nice. What was timing and boost?

                        Comment


                        • #13
                          FZR-R3 Turbo build

                          Originally posted by hotbutta View Post
                          Nice. What was timing and boost?
                          18psi with boost leak and 30deg timing.

                          Boost leak wasn't located until I stripped everything down to go turbo. Ended up changing everything from the wheel to piping to BOV to intercooler and at the end it was the vacuum block where it connected to the MAP sensor.

                          Thankfully I found it or else I would've had the same problem with the turbo setup. I'm now waiting on the engine to arrive so I can start testing again. Currently using a block and head that was laying around to get a head start on fabricating the turbo kit.
                          Last edited by R3_killa; 05-15-2022, 06:48 AM.
                          2010 FZR - Turbo build loading...

                          GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

                          Comment


                          • #14
                            Originally posted by Reaper9789 View Post
                            Looking good man. Its going to be one hell of a ski. I always worry about running lake water straight to the turbo, cold water could cause an issue on startup. My 2021 pump parts should be coming in soon and I will run a dedicated line to cool the turbo and dump the rectifier overboard.
                            The line will go from strainer, to up-pipe, turbo cartridge, downpipe and out.
                            My BW 67/58 center section has been lake water cooled since 2015. Not a single issue....and yes, it is a iron center section, not aluminum.
                            2013 RXT-X260 - GRF BorgWarner EFR 67/58 Turbo/MoTeC M130
                            Build Thread: http://www.greenhulk.net/showthread.php?t=231361
                            Kicker audio:http://www.greenhulk.net/showthread.php?t=215264&highlight=kicker
                            https://wfoperformance.net/sites/us/...5/web/home.htm

                            Comment


                            • #15
                              Found a description of the R&D thermostat block cooling kit and seems my engine cooling is right in the money given my recorded data.

                              Is there any other data to suggest otherwise in regards to peak power at particular temps?

                              Click image for larger version

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                              2010 FZR - Turbo build loading...

                              GPR-HO (1.8L) - Ribbon delete, Oil catch can, DIY engine cooling, Hi-flow strainer, Free flow exhaust, Modded water-box, 14/17 prop, Modded ride plate, SS grate, Pump seal kit, TBM pump cone kit, Sponsons, Steering system and DT reflash - 7800+RPM

                              Comment

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