RB Racing Harley Turbos

Click on image or text above for your motor. Scroll below for a bit of fabrication examples.

Fixtures and a lot of knowledge are required to make turbos for EVOs Twin Cams, VRods, Race Bikes, and specialized ORCA motors with Bosch Fly By Wire Motorsport Controllers etc...for both Bonneville and Street bikes. These fixtures are just the tip of the complexity involved. 44 years 1980 to 2024.

Pallets of raw parts, thousands of dollars in waterjet and laser cut parts and mandrel bending, plus over 1000 pages of documentation, software, CAD files, many three ring binders, and hopefully not too much brain fade.

Details: Intercooler Fabrication

Here we are welding up a 300+ HP HD Turbo Intercooler after machining and prepping the parts for it. Air enters and exits at the larger part of the tapered end caps. After this the intercooler goes for ceramic coating. This chews up a couple of days off and on. Expensive.

The intercoolers are sized to drop the inlet charge temperature closer to ambient i.e. if the charge temperature pre-intercooler is 150F and the outside air temperature is 80F and the bike is moving at cruising speed and then under acceleration, at say 8 PSI, then the inlet temperature will be closer to the ambient 80F.

Use our Intercooler Calculator to see what your bost inlet temperatures are.

Various spigots for turbo connector hoses..EVOs, Twin Cams, OEM EFI systems, Cosworth Pectel FBW systems...For our intercoolers and plenum chambers. Does get a bit complicated, but with specialization and the intended uses, it always does.

Twin Cam Ns EVO: Genuine Garrett Turbo.... Raw Castings

Start out with a genuine ceramic ball bearing Garrett Turbo...Add custom housings and you are at $1,500.00 before we start modifying things for a Harley V-Twin.

They just don't fit optimally the way the come...so we have to do surgery.

We use genuine Garrett Ceramic Bearing 360 HP Turbochargers. These come in as raw, machined castings in iron and aluminum. We then modify the compressor, exhaust housing and the turbo center section with machining. welding, sanding, and bead blasting operations. The parts are then ceramic coated internally and externally for corrosion protection, heat retention, and heat dispersion. With more that 25 years going to the Bonneville salt flats, we know how importatnt anti-corrosion coatings are...not to mention operation in the real world.

Then there are the 44 years of previous fixtures dating back to Shovelheads and parts which have since been discarded. Gets expensive. Thousands of man-hours.

Many Hours Later..Orca Turbo Pod

Cutting, machining, welding, anodizing, water jet cutting, ceramic coating, fixturing and assembly operations...It is no longer a $1,500.00 turbocharger but an Orca Turbo Pod that will go past 300hp and 25 psi of boost. Whatever it takes to make your 850lb Harley Dresser move. Past 200hp @12 psi. Dial the boost from your handlebar when you are riding.

On a Twin Cam 95" the turbo puts out about 165hp and 164 ft/lbs torque @ 9 PSI of Boost.

Annealed Copper Turbo Gaskets

Cut with a water jet... Heat Cherry Red with torch then drop in cold water. Turns copper into a soft condition. We anneal all our turbo and wastegate gaskets. No goo or silicone.

Wastegate Testing

With three regulators we test Boost Pressure, Exhaust Back Pressure, Adjustable Boost 8-25 PSI, and wastegate valve sealing. Here boost is controlled by a pneumatic controller. With advanced Electronics we can control the wastegate with Phase and Anti-Phase fast acting solenoids.

300Hp Intercoolers

RB Racing Harley Turbocharger System: Intercoolers Coated in Ceramic Black High-Emissive Coating for optimal performance and corrosion protection. You can run your big twin through the gears at low boost and about 180 Hp and the intercooler discharge temperatures will be close to ambient. We don't use small restrictive intercoolers or, even more stupidly, put the intercooler under the bike like one firm does.

Airflow in and out of the intercooler must be smooth so each of the 13 channels flows the same which is why the hats must be tapered. You cannot simply butt the turbo discharge up against the base to the intercooler as some firms do.

Front view left above. Rear view right above. The intercooler mounts securely with billet clamps to the crash bar. The intercooler is rigidly mounted and the turbocharger and turbo plenum move with the rubber mounted engine. Special flex bellows couplers (see below) connect the moving and stationary parts. Proven in years of use.

Turbo Plenum Chambers: All machined from billet and welded. Integral boost and water injection ports plus billet compressor discharge valve. No nuts, no bolts, no windows, and no blow through filter. Designed as a surge reservoir and to break up directional airflow before it enters the throttle body. We have five variations on these to cover multiple applications.

Oxide blasted and ceramic coated with a heat dispersant ceramic.

Plenum for our RSR EFI Systems with 56mm Throttle Body: Idle Air Control Stepper Motor, Compressor Discharge Valve, Boost reference port.

To protect our Harley Turbo Intercoolers against corrosion and to dissipate heat we use special Ceramic Heat Dispersant Coatings which are applied after we fabricate and blast the parts. These coatings are impervious to carb cleaners and other chemicals as well as normal soap and water cleaning. This is not powder coating as that would be an insulator and degrade the intercoolers efficiency. Plenum chambers are also coated.

Twin Cam 88 Plenum Chamber. Optional water injection port.