P13222: Turbocharger Integration
/public/

Build, Test, Document

This page is dedicated to documenting detailed design revisions, manufacturing, and implementation of the GT06 Turbocharger system on the engine.

Many components beyond the turbo itself need to be modified to implement the system with the existing engine. All the modifications made have been documented in the images and descriptions below.

Build, Test, and Integrate

Detailed Modeling Revisions
View Behind Driver's Seat

View Behind Driver's Seat

View Behind Car

View Behind Car

Engine Model Side View

Engine Model Side View

Engine Model Rear View

Engine Model Rear View

CFD Simulations

Intercooler Flow

Intercooler Flow

Intercooler Velocity Plot

Intercooler Velocity Plot

Radiator Flow

Radiator Flow

Radiator Velocity Plot

Radiator Velocity Plot

Intake Plenum and Intercooler Internal Flow

Intake Plenum and Intercooler Internal Flow

2013 WR450 Race Engine

New Engine from Yamaha

New Engine from Yamaha

Turbo Modification

Cut Exhaust Manifold

Cut Exhaust Manifold

Modified Exhaust Flange

Modified Exhaust Flange

Titanium Exhaust Manifold Replacement Manufacturing

Titanium Exhaust Manifold Replacement Manufacturing

Physical Size

Physical Size

Weight Savings

Weight Savings

Intake Plenum

Plenum Mold

Plenum Mold

Carbon Plenum Halves

Carbon Plenum Halves

Intercooler Weight Reduction

Before/After Modification

Before/After Modification

End Tank Mold and Cured Part

End Tank Mold and Cured Part

End Caps for Intercooler

End Caps for Intercooler

Exhaust Manufacturing

Bent Titanium Tubing

Bent Titanium Tubing

Wall Thickness

Wall Thickness

Titanium Welding Tank

Titanium Welding Tank

Welded Exhaust with Flange

Welded Exhaust with Flange

Engine Modification

Aftermarket Connecting Rod

Aftermarket Connecting Rod

Lightened Flywheel with Timing Ring

Lightened Flywheel with Timing Ring

Timing Ring View 2

Timing Ring View 2

Injector Placement

Injector Placement

Injector Spray Pattern

Injector Spray Pattern

Swain Low Temp Engine Coating

Swain Low Temp Engine Coating

Fuel Cell Manufacturing

Fuel Cell Manufacturing

Test Plans & Test Results

Dyno Test Stand

Turbo Setup on DC Dynomometer

Turbo Setup on DC Dynomometer

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