what have I gotten myself into now...

Patrick · #1 7th December 2008, 18:06

....

on another note I put 80 miles on the Sportster this weekend, I'm hoping for more dry weekends before the end of the year!

The Bridgestones are getting a bit old now and are feeling a bit very loose on frosty patches! Think I may have to swap the front tyres out too if I'm going to do much more cold weather driving. Oh and I need to fix the heater, it sounds like something caught in the blower.

GreatOldOne · #2 7th December 2008, 19:59

What have you got yourself into? 4 throttle bodies, 6 cylinders... How does that work? Go on, you're dying to tell us.

Patrick · #3 7th December 2008, 20:19

Quote:

Originally Posted by GreatOldOne

What have you got yourself into? 4 throttle bodies, 6 cylinders... How does that work? Go on, you're dying to tell us.

I need half of another set which will make up a 4+2 = 6. They are from a GSXR 600 K3. The great thing is they unbolt and turn into individual bodies so that they can be spaced to fit an M20

I just need to get another set cheap off eBay to get the extra two I need to complete the set. This its a case of figuring out how to attach it to the head.

cabrioman · #4 8th December 2008, 11:34

I looked at this for my Cabrio, think you may find it needs more than just finding a way to fasten it to the head.

The research I did indicated the only way to get them running is by using an aftermarket ECU such as Omex, Emerald etc then you still have to map them to the engine, sort out the fuel rail, etc etc it starts to get quite expensive.

John

Patrick · #5 8th December 2008, 11:47

Quote:

Originally Posted by cabrioman

I looked at this for my Cabrio, think you may find it needs more than just finding a way to fasten it to the head.

The research I did indicated the only way to get them running is by using an aftermarket ECU such as Omex, Emerald etc then you still have to map them to the engine, sort out the fuel rail, etc etc it starts to get quite expensive.

John

Yeah it will need custom mapping, I'll probably look at building a mega squirt ECU or buying an assembled one. Also means I can drop the AFM. I had planned on switching to stand alone at some point anyway

Patrick · #6 2nd January 2009, 20:23

Another ebay bargain:

... I can't understand why nobody wanted a red intake manifold

I also got a second cheap set of GSXR 600 throttles!

And a few hours with the angle grinder, hack saw and then time with the milling bit in the lathe's piller drill:

A pic from the other side of the manifold that's on the car now:

Ordered some Ali pipe today and silicon tube. I just need to find somebody who can weld cast ali and this will start to come together!

The nice thing about using an inlet manifold as a base is that it will fit right on and you don't need to worry about the oil return. I'll do a bit of port matching to finish it off on the spare head I've got

Patrick · #7 2nd January 2009, 21:36

Found some photos of the milling work:

peterux · #8 2nd January 2009, 22:18

Wow, this makes my e46 engine installation look easy (and it isn't!!

)

You will certainly have a unique installation if this works...

Patrick · #9 2nd January 2009, 23:22

Not sure I'd want to tackle your wiring nightmare! I think to get this to work right I will need VEMS or Megasquirt!

Should sound good if nothing else

Patrick · #10 4th January 2009, 18:13

Two sets of ITB's give you 4 bolts to screw them together - not long enough for 6 throttles. The solution is to chop the thread off two of them and the head off the other two. Then the 4 bits are welded together to create two long bolts.

After welding the join is ground down to make it round and smooth

Which means with temporary spacers its all one piece now

MartinClan · #11 5th January 2009, 16:26

Quote:

Originally Posted by Patrick

Found some photos of the milling work:

Hi Patrick

What model of lathe is it that you use? I have been thinking about buying one although I haven't used one since school which is rather longer ago for me than you lol.

Robin

Patrick · #12 5th January 2009, 17:15

Quote:

Originally Posted by MartinClan

Hi Patrick

What model of lathe is it that you use? I have been thinking about buying one although I haven't used one since school which is rather longer ago for me than you lol.

Robin

It's an EMCO Compact 7 long bed bought 33 years ago by my dad

MartinClan · #13 5th January 2009, 17:53

Quote:

Originally Posted by Patrick

It's an EMCO Compact 7 long bed bought 33 years ago by my dad

Thanks Patrick

Robin

Patrick · #14 5th January 2009, 19:34

I've just double checked, its an Emcomat 7 - the compact 7 is the modern version

Patrick · #15 10th January 2009, 21:36

A bit more progress today in preparation so the manifold can be completed. I couldn't quite run the pipes at the same angle as the holes in the head due to using the stock manifold. I've opted for a shallower angle that will result in a relatively smooth transition between the pipes, manifold and head. I could always completely custom make a manifold at some point in the future.
The other big step was to get the throttle bodies properly spaced. I cut 10 spacers on the lathe exactly 11mm wide. There still a lot to including the minor issue of welding the pipes on - not sure how this will work but I suspect it will involve doing a lot of grinding to clean it up!

Ali tubes cut

Quick test fit

"just" needs to be welded!

And from the other side (yeah the throttles are the wrong way round ;o) )

Spacers cut on the lathe to space each throttle 11mm wider than they are on the GSXR

MartinClan · #16 13th June 2011, 12:29

Patrick

I know this is an old thread but....

Can you tell me what size choke the throttle bodies have? I am looking for some individual ones for the next project to go with the Megasquirt kit I have just bought...

Cheers, Robin

Patrick · #17 13th June 2011, 20:37

I need to dig the box out, not had time to even look at this since my last post

MartinClan · #18 14th June 2011, 07:32

OK - thanks. Whenever you have time. It's a long term project....

Cheers

Robin

denniswpearce · #19 14th June 2011, 18:17

My knowledge on this subject will fit on a postage stamp. So I am lost with what Patrick is trying to do. I know the fuel intake system that exists is fuel injection but my limited knowledge fails to understand what Patick is trying to build and what the object is ?
Is he trying for more power or an alternative way to inject fuel ???????????
So would anyone care to explain to the unitiated please.

MartinClan · #20 14th June 2011, 19:58

I think the theory is that ITB's (Individual Throttle Bodies) get more air (and hence fuel) into the engine and hence more power. It also means all the cylinders get the same charge - in theory probably more efficient - but I don't think that was Patrick's aim....
ITB's are often combined with an aftermarket ECU where you can play with the fuel/air mixture (like a carb) - again more power and efficiency.

Robin