Another ITB build thread

[supaninja]

Roy- it might be easier to have the pulley's on the same side, both to the front or both to the back. Since your not using the injectors in the TB's that lets you have a little more "creative freedom" with your TB orientation.

[Devastator]

Looking good Roy!
That pulley looks great mounted up and seems like it'll do the trick for you.

[grelland]

Roy- it might be easier to have the pulley's on the same side, both to the front or both to the back. Since your not using the injectors in the TB's that lets you have a little more "creative freedom" with your TB orientation.

Yes I know, but somehow I am put off by the fact that the idle air screws will be on the inside on one side, and the outside on the other.... I know....

[grelland]

Looking good Roy!
That pulley looks great mounted up and seems like it'll do the trick for you.

Perfect fit, and looks good also

[grelland]

So I decided to go for the route supaninja proposed, and will flip the LHS TB 180 degrees, so they both have the pulleys at the rear of the shroud. I made a bracket, but could not find my M6 tap, so I have to visit the HW store tomorrow so that I can mock it all up...

A friend of mine started welding the intakes yesterday, and plan to be done by tomorrow, so I will then be able to trial fit everything and make the cables for the TBs.

I also cleaned up the TBs a little by grinding off all the unneccesary brackets, and fitted the lower plates for the filters. The air horns have a flange at the bottom that just barely covers the gap from the IDF holes that are spread further apart than these TBs.

TB.jpg

[supaninja]

That is looking slick Roy!

[grelland]

Thanks, Nick.

Progress is slow, but I got a couple of things done this week.

First I had a look at the LHS TB, and mocked up a holding bracket for the cable adjusters. So far it is definately a case of form follows function, but if it all fits, I will clean up the bracket and maybe find some paint.

TB LHS.jpg

Then my son has a project to clean up the engine bay, and one of the things he is working on is to make a couple of 3mm alu sheets to fit on the "firewall" that separates the engine bay from the area over the gearbox.

Here's the RHS where we put in a bulkhead AN-6 fitting for the fuel supply and a rubber grommet for the main power wire from the generator to the battery:

firewall.jpg

Then a package arrived in the mail with some more fittings and hoses, and this is how the breather box will be hooked up. I will use black nylon braided hoses.

breather.jpg

Tomorrow I will go snowboarding with the kids, so more slow progress

[M3D]

THIS LOOKS GOOD BUT IT IS A LOT OF WORK
Would a set of old carbs do the same thing with injector bungs ?????

[Piledriver]

THIS LOOKS GOOD BUT IT IS A LOT OF WORK
Would a set of old carbs do the same thing with injector bungs ?????

A set of old carbs are potentially worth $$$ and would be more work if you wanted a cable pull linkage.
There's really two sub-projects going on here.
...there are simpler options, but these TBs were designed for this style of cable pull, so...

Plus on carbs you still have to block off the jets etc so you don't have a constant vacuum leak.

These OEM TBs are beautiful quality and can be had all day long for <$100 with well sized injectors and rails, usually low miles due to the Donor Principle of Motorcycling.

Someone should be making "off the shelf" T1 and T4 manifolds for them, at least for the GSXR TBs.
(I suspect that's in the works for some definitions of "shelf"...)

[Piledriver]

Has anyone checked to see if those TBs are aluminum or zinc?

I was considering trying to simply weld them on some cut down manifolds if weldable.
It's not like you'll have to soak them in carb cleaner.

[Max Welton]

THIS LOOKS GOOD BUT IT IS A LOT OF WORK
Would a set of old carbs do the same thing with injector bungs ?????

Bah. Tinkering is it's own reward.

Max

[supaninja]

THIS LOOKS GOOD BUT IT IS A LOT OF WORK
Would a set of old carbs do the same thing with injector bungs ?????

Bah. Tinkering is it's own reward.

Max

Damn right, buying something from a company that is ready to plug and play is soooooooooo boring

[grelland]

Could not agree more

Since I still have not invested in a TIG welder yet, I had a friend help me and here's the result so far:

weld.jpg

Not too shabby in my mind.

I then drilled the mounting holes in the flanges and mounted it all on the engine in order to cut and fit the cables:

left tb.jpg

right tb.jpg

Then a picture of the entire engine with the odd angle of the TBs and almost invisible cable setup:

engine.jpg

Starts looking good in my mind.

The next thing to do now is to open up the holes for the injector holders, and have them welded. Then I can fit the fuel lines, and finally put the engine back in the car.

Here's a pic of the outside of the TB/intake, and in my mind this will be a fairly effective setup with a minimum of curves for the air to flow:

tb outside.jpg

[supaninja]

Hot damn that looks awesome! Flipping the left TB sure made the linkage simpler and more like it is supposed to be.

[grelland]

thanks