Another ITB build thread

[Dale M.]

How about these....

http://www.ebay.com/itm/S57-Suzuki-GSXR ... 5890b29596

http://www.ebay.com/itm/02-Suzuki-GSXR- ... 256952ea49

http://www.ebay.com/itm/01-02-GSXR-1000 ... 3a6c4b74b4

Or make me offer on set I have.... I have the sames GSXR unit and they are unmolested...

Dale

[grelland]

I also have a piece of alu stock, so I might make my own flanges in stead of using the ones cut off from the manifold. No big deal, really

[Dale M.]

Not to take from this thread but some of the"issues" are addresses here also...

http://www.shoptalkforums.com/viewtopic ... 3&t=137795

Dale

[supaninja]

Grelland- I'm in the middle of making the linkage "right" and decided to put the spigot flanges on a 38mm TB (good thing too because I need to clearance where the return spring hooks onto the pulley). I got 2 things going on right now: making the 01-03 600 pulley fit on the right 04-05 600 TB, and finally the weld plate template.

The pulley fits with a little bit of modification, looks like it was OEM for that TB. Tomorrow I'll make a little time for the cable bracket, very simple design.

I have staring at my engine bay, scratching my head, trying to figure out the best way to with the new manifolds. I don't have a lot of room on the engine tin side, so I rotated the spigot flanges to similar bolt pattern as IDF's. That gave me about a 1/4" more space(better then nothing). I had also bought M6 button head bolts to mount them, derrrr, M8's fit a lot tighter. I still want to go with button heads over studs and nuts, I figure it will be easier to install the mani's with the flanges already bolted on and then just clamp the TBs on afterwards. I already foresee a huge headache when it comes time to get a socket down there with the ultra shorty manifolds.

One other interesting observation is the spigot flanges will put the TB's 5/8" above the manifold, They don't seat down as far as I thought they would. When they are push on they are on there really good, I don't even have to super tighten the clamp. They should be more then enough for a boosted application, giggity.

Damn I wrote a novel, lol.

[grelland]

thanks for the info let us know how the pulley and bracket comes out.

I started some real work today, and before I dug into it, I took a better picture of the old configuration:

I saw a couple of worrying issues when dismantlig everything; one of them being that it seems my fuel lines have swollen, and there were some leaks.... From now on, I will stick to an-6 couplings and better quality lines....

I also see that I need to repaint my engine bay...

After removing all the porsche cooling parts, and the runners and plenum, I mocked up the t1-shroud:

Looks ok...

But this being a stock 1600 doghouse shroud, it is too wide, and I will have to modify it a little to gain clearance to the TBs:

The red line indicates where I will make a cut. I will also move the hose connections inwards, as I will like some heat in order to prolong the season as much as possible.

I also have a pair of tall filters, and even with my short manifolds, there is not that much room above.


I also need to move the EDIS coil pack, if I decide to keep it:


I think I have seen what I need, so the next thing now, is to remove the engine from the car and the real work can start

[supaninja]

Looks like a winner, keep us updated with your progress! I'm curious how you end up going with your linkage, I am using 2 gsxr throttle pulleys, but it might be easier to have custom ones made. I'm also interested in how you end up mounting your injectors. With those huge air filters you should have plenty of room to fit 45 DCOE velocity stacks http://www.ebay.com/itm/SINGLE-VELOCITY ... 1e67eb78e8

[grelland]

I'm curious how you end up going with your linkage,

Me too

One day I am on a cable solution, the next I am on a linkage one... time will show...

[supaninja]

Once I got matching pulleys I fell in love with the motor again, I'm just saying

[grelland]

Finally I had a moment to spare, so I dug into the fabrication of the flanges.

I started by outlining the spigot flanges on a piece of 10mm alu:


Then I drilled the holes with a decent quality hole-saw:


I made the holes with the center-spacing identical to the TBs so I might keep them paired.


Finally an internal picture, the hole in the flange is some 1mm larger than the rubber flange; I hope that will not be a problem


I am not completely satisfied with the fit against the cut-down manifold, so I will see if I make some adjustments prior to welding

[grelland]

Had some discussions with a couple of friends, and someone asked me why I need the TBs to be horisontal. I had no good answers, and made a quick mock-up to see how it would look if I made a manifold where the runners and TBs are more in-line:



It looks more "unusual" than "ugly" I think, and it leaves me more room for the injectors.

Will probably not work in a Bug, tho

[Clonebug]

That would save you from having to cut and modify the cooling shroud which would be a good thing.

Clonebug

[grelland]

yup

and the air does not have to turn some 40deg in the runner

[sideshow]

...One day I am on a cable solution, the next I am on a linkage one... time will show...

If you get the throttle bodies low enough (under the alternator) a simple bell crank like the CSP'ish would fit great.

[Steve Arndt]

The sprint car Hilborn injection that Autocraft used were setup just like that. Go for it!

[Dale M.]

Why not.... You don't have any "floats" to worry about....

Dale