| Phase 2 |
| 05/24/09 - Turbochager |
| May 24, 2009: I got the Aerocharger 53 Series turbocharge and started sketching out the layout. |
 |
 |
May 31, 2009: I choose to mount the turbocharger in the location of the stock Catalytic converter. This will make for a minimal amount of exhaust plubing to be fabicated and very clean installation.
My plan was for the turbo bracket/intake pipes to be a direct replacement for the CAT only. Unfortunitly it wasn't possible. It was about 3/4" off. So the lower horizontal head pipe will need to be modified. I have some U-Bends on order now. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| May 31, 2009: Inside the stock Ducati Hypermotrad Catalytic Converter. |
 |
 |
 |
| June 6, 2009: Exhaust intake complete and turbo mounted. I need another U-bend to complete the exhaust output pipe. The steel portion of the air-tube is complete except for welding and the Samco silicone hose has been order. I'll be using the stock mid pipe with the flapper valve removed. I'll also be using the stock slip-ons (cored to reduce back pressure). |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
Air-Tube Path:
Blue=Steel
Red=Samco Silicone Hose |
| June 6, 2009: Inside the stock flapper valve. |
 |
 |
| June 21, 2009: The exhaust intake pipe, output pipe and mid pipe are all complete. The steel portion of the air-tube complete too. Waiting for the Samco silicone hose to for the air-tube. I'll going to wait till the end of the project to core the stock slip-ons. I mounted the 1098R kickstand and got it ready to be welded. Once the bike is up and running, I'll send the pipes and air box out to be ceramic coated. I'll start laying out the steel air box next. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| June 27, 2009: Did a detail inspection of the stock air-box and how everything arounds it fix's or attaches. Looks likt the coils attached to the air box, so i'll need to simulate that too. I then cut my spare air-box into to see how the inside was structured. |
 |
 |
 |
 |
 |
 |
 |
 |
| June 27, 2009: After reviewing all my notes and sketching out a rough design, I built a 1:1 scale 3D mock up of the air-box out of foam core. Once I satified the mock up with fit. I'll take it's meausrements and draw out the design in 2D and have all the parts water-jet cut out of thin plate steel. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| July 5, 2009: I finilized the size and shape of the air-box [(445cc + 220cc) > 539cc]. I'll send artwork to the water-jet cutter Monday morning. I already have an order placed for a set of 51mm velocity stacks. |
 |
 |
 |
| July 8, 2009: Got the water-jetted metal plates back (0.0625" 304 Stainless). As soon as I get the velocity stacks and the spacer rings in I'll tack it all together. |
 |
 |
 |
| July 14, 15, 25 & 26, 2009: Got all the parts and built the new air-box (approx 665cc plenum chamber). Had the rearsets anodized black (interesting result with the shifter lever). Got the custom boost gauge in. I ordered the real AeroCharger. As soon as the RapidBike system get's here I can ceramic coat the exhaust and air-box. Then it's ready to start tuning! |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
Two piece lever. The wedged aluminum didn't conduct the electricity! The perfect sealed wedged, what's the odd's. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
Ducati Porcupine? |
 |
 |
Custom DucCutters
Boost Gauge |
 |
| Rebuilding my buddies ProCharger (Centrifugal Supercharger). Check out the old bearings! Cleaned out the oil pathways and he was good to go. |
 |
August 2, 2009: All the hardware is complete! (about five full days of production time)
I hoping to return the mock up turbo and place the order real unit today. I'm also hoping the distributor will call me back with the price for the RapidBike system today, so I can get it ordered. I don't understand why both are dragging there feet...
I still need at add the MAP sensor and the pressure link for the Aerochargers controller valve to the air box. I'm just waiting till I get the MAP sensor which will be part of the RapidBike system. Once the airbox in 100% I'll send it and the exhaust system out to be ceramic coated by HPC.
Things to do, while I'm waiting for the turbo and electronics... I cut the extruded aluminium heat sink into shape. I just need to grind and polish it up before mounting it to the ceramic coated air box when its finished (Artic Silver Thermal Compound). I also need to install the custom boost gauge. It will be placed in the lower left corner of the carbon fiber dash. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| August 21, 2009: Rapid Bike Mod 3 system arrived. I have it all layed out any ready to go. The Aerocharger should be here by the end of the week as well. I still need to get the ceramic coating done, so I'm hopping to do the final assembly during Labor Day weekend. |
HY-RB-Turbo Harness |
- 1: Negative ground
- 2: Map switch
- 3: Quick Shift Sensor
- 4: PC connector
- 5: Rapid Bike Mod 3
- 6: MAP sensor
- 7: Horizontal injector connector
- 8: Vertical injector connector
- 9: Pick-up connector
- 10: Rear brake light (power supply)
- 11: RB o2 trimmer module
- 12: PC connector cable
|
RB o2 Emulator Harness |
| August 25, 2009: Received the Aerocharger! |
 |
 |
 |
 |
 |
101/240 - 7 psi |
| September 13, 2009: Cored stock mufflers, installed Rapid Bike harness and installed boost gauge. Still waiting on exhaust system to return from HPC. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| September 18, 2009: Got the exhaust system back from HPC and started assembling the air box. |
 |
 |
 |
 |
 |
 |
| September 21, 2009: Prepped Aerocharger and started finial installation including RapidBike, boost gauge, aerocharger and exhaust. |
 |
 |
 |
 |
 |
| September 23, 2009: Installation continued... |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| September 29, 2009: Mechanical work complete! The bike is all back together and I delivered it to "Tom's Italian Tune & Service" for helping tuning it. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| November 11, 2009: Tom (Tom's Italian Tune & Service) was able to talk RapidBike through remaking the new wire harness. I took the first "Turbocharged HyperMotard" for it's first test ride. Everything went well, so I rode it home. After a few test rides, Tom and I we'll take it to the Dyno for final tuning. |
 |
 |
 |
VIDEO: HyperKromo Startup (YouTube.com)
VIDEO: HyperKromo First Test Ride (YouTube.com) |
| Dec 14, 2009: Finial got the correct RapidBike software to try and tune the bike... |
 |
 |
| Jan 11, 2010: New parts and maintinance... |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
| Jan 18, 2010: Made several updates to the bike this weekend. Some cosmetic, some performance. Including adding some more fiber carbon parts, Rizoma clutch cover, Rizoma pressure plate and Zard slip-on. I also wired in the ground effects lighting. |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
 |
Click Here For Phase One Photo's. |
