ITB Project

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ITB Project; ITB's from Suzuki GSXR 600 for M20
Topic Started: Mon 5 Jan 2009, 12:15:51 (91 Views)
JazzMan	Mon 5 Jan 2009, 12:15:51 Post #1
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	I've been toying with the idea of ITB's for a while so I've started using throttle bodies from a GSXR 600 K3, here's my progress so far: Two sets of these GSXR 600 K3 throttle bodies: A spare M20B25 intake manifold A number of hours with a hack saw, angle grinder and piller drill on the lathe with a milling bit later: And you get a nice manifold ready for some ali tubes to be welded on: The manifold will slot right on being the mounting face of a stock intake as can be seen below: The nice thing is that the provision for the oil return is already integrated to there's not need to come up with a solution for that: The stock fuel injection locations will be used, those on the GSXR will be plugged. The GSXR individual throttles need spacing further out than that standard so some modification will be required to make this work. The K3's have a second set of throttle butterflys controlled by the ECU, these will need removing and the extra holes plugging. The end piece as a TPS integrated. The diameter of the GSXR bodies is 38mm at the engine side, they are tapered and open up a bit more to the intake side. Based on what I've read on the Zone. The plan is to use tubing to connect the throttles to the manifold so that its possible change the lengths and see what the does to the power! 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 :) Edited by JazzMan, Mon 5 Jan 2009, 12:16:31.
	M20 Powered Marlin Sportster


Mart	Mon 5 Jan 2009, 19:31:39 Post #2
Moderator Posts: 3,464 Group: PE30 Members Member #343 Joined: 5-01-06	Forgive my ignorance Patrick, but what benefits will this give over the stock items? As you can see my knowledge of all yhis is nil Nice bit of engineering though mate !!! that I do know about. Mart.
	Nice one Cloud


JazzMan	Mon 5 Jan 2009, 20:54:34 Post #3
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Mart Mon 5 Jan 2009, 19:31:39 Forgive my ignorance Patrick, but what benefits will this give over the stock items? As you can see my knowledge of all yhis is nil Nice bit of engineering though mate !!! that I do know about. Mart. Sharper throttle response and minus the AFM and a good map on standalone ECU more power. You can equalise the amount of air going into each cylinder as well by adjusting each flap individually :) And it sounds cool :D Some examples: http://uk.youtube.com/watch?v=XZV6ir0fzP8 http://uk.youtube.com/watch?v=5xkvDgsf3Qc http://uk.youtube.com/watch?v=aAwATJv0-2g
	M20 Powered Marlin Sportster


Mart	Mon 5 Jan 2009, 22:13:52 Post #4
Moderator Posts: 3,464 Group: PE30 Members Member #343 Joined: 5-01-06	Nice one Patrick , I see what you mean now with the balance of each cylinder. Does this mean that you can compensate also for the compression difference of each pot, and is all this "control" via a lap top / soft-ware?. My good friend has been on this type of thing with his kit car (sorry for the term) and he has lost faith which I am suprised at. If this is on your web site , I will pass this on to him . Cheers Patrick . Mart.
	Nice one Cloud


JazzMan	Mon 5 Jan 2009, 23:16:58 Post #5
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	yeah it's posted on my website :) To balance them you use vacuum gauges, ideally all 6 at once and you just dial them in so they match with the engine running. You plug each gauge into a cylinder and get a reading when it's running. There's lots of 2 and 4 way ones on eBay for not too much. Search for vacuum balancer gauge or carb balancer :) The fun bit will be getting it running and tuned in!
	M20 Powered Marlin Sportster


JazzMan	Sat 10 Jan 2009, 22:37:09 Post #6
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	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
	M20 Powered Marlin Sportster


Mart	Sun 11 Jan 2009, 17:06:17 Post #7
Moderator Posts: 3,464 Group: PE30 Members Member #343 Joined: 5-01-06	Nice one Patrick , keep it all coming please. By the way , if you have any questions on engineering/machining dont hesitate to ask mate. Mart.
	Nice one Cloud


JazzMan	Sun 11 Jan 2009, 17:30:45 Post #8
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Mart Sun 11 Jan 2009, 17:06:17 Nice one Patrick , keep it all coming please. By the way , if you have any questions on engineering/machining dont hesitate to ask mate. Mart. Will thanks very much :) I think I'm going to get a pro to do the welding, test attempts so far just look like bird poo!
	M20 Powered Marlin Sportster


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