Turbo CB400F
This was a project that in hindsite consumed way to much time and effort. At the time I thougt thatdesigning and building a bike from scratch wihout constraints would be easier than building something with adapted bodywork/frame etc.
Turned out I was wrong. I completely designed this bike in Solidworks 3D before I ever started building it. The upside of doing things this way is that you are pretty sure that things are going to fit before you start building and you can run Finite Element Analysis design studies on parts and assemblies to ensure an adequate Factor of Safety on critical components.
The downside is the ability to continually redisign and redisign to the point where years can pass without actually building anything. A design like this is a compilation of systems, and revising one system can have a snowball effect, where just changing the length of the shock for instance, can mean a design change for the swingarm. linkages, frame mounts, bodywork, even all the way up to the triple clamps.
At some point you have to just stop and build. The first incarnation had fairing lowers.
This year I made some changes to the oil pan that effected the fairing and belly pan mounting. The belly pan survived, the fairing didn't.
Here are the specs of the build:
Engine
Honda CB400F 4 cylinder, air cooled
Capacity - 400cc - 51mm bore x 50mm stroke
Compression ratio 9.4:1
Redline 10,000 rpm
Stock power - 37HP @ 8,500 rpm, 24 lb-ft @ 7,500 rpm @ the crankshaft
Calculated power @ 10 PSI boost - 65HP, 44 lb-ft torque @ the crankshaft
Measured HP at wheel via G-Tech instrument - 54HP @ the wheel
Intake - Turbo>Intercooler>Upper Plenum>2 x 38mm CBR600RR throttle bodies>Log Style Lower Plenum>Injector Bodies
Intercooler - Bell core with custom end tanks
Turbo - Chinese VZ-21 (IHI RHB31 clone)
Stainless exhaust collector - hand built. Akrapovic titanium muffler
ECU - Microsquirt v3
Custom 12-1 trigger wheel, CBR600RR VR sensor
CBR600RR lower injectors (4) in custom injector bodies
CBR600RR Throttle Position Sensor
CBR600RR Fuel Pump
GM Air Temp Sensor
GM Coolant Temp Sensor
GM 2 bar sensor for MAP
GM 1 bar sensor for atmospheric Baro
Bosch 4 tower Logic Coil - Wasted spark
14Point7 Spartan 2 Wideband O2 controller/Bosch LSU 4.9
Other Engine upgrades
APE upgraded cylinder studs
Heavy duty cam chain
Barnett clutch plates
CBR600RR charging system
Hand built oil pan to accommodate turbo oil draining
CNC oil filter plate to fit oil cooler/turbo feed lines and fit a spin-on filter
Earl's curved oil cooler
Dished sprocket and bearing support to fit wider rear wheel
Chassis
Wheels - Spun Aluminum Rims, CNC machined hubs and spokes. 120 x 17 front, 160 x 17 rear
Front Forks, front disk, front caliper, front axle - CBR954RR
Triple clamps and clip on bars - CNC
Frame - Hand built 1028 ERW mild steel, 6061-T6 plate
Subrame - CNC 6061-T6
Swingarm/shock - Aprillia Mille swingarm (narrowed), CBR600RR shock. Steel rocker Link (mimics CBR600RR ratio)
Rear disk - CBR600F1. Rear Caliper - Brembo. Rear Master cylinder - Honda CR250
Body
Fairing mount, headlights - Buell Firebolt - magnesium
Fairing - Carbon Fiber
Front Fender - Carbon Fiber from unknown Yamaha - Hand formed and CNC aluminum mounts
Gauges - Koso RX-2, Accell boost gauge
Shorai Lithium battery
Custom Wiring harness
Tank - Hand formed 3003 aluminum
Seats - Hand built
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