I would like to fit some GSXR750 throttle bodies to an S3 Zetec engine which will need a custom manifold. It doesn't look too difficult, but I don't have the equipment (or skills for that matter) to do the job. Anyone got access to a TIG set and are a dab hand at this type of fabrication?

Chris

U have U2U!

garage19 could you "u2u" me too as i am in a remarkably similar postion to chris

cheers

[Edited on 12/8/05 by liam.mccaffrey]

<----- No custom manifold here

http://www.bubs.net/Fury/throttlebodies/

But if you want to go the custom route, concept racing did Ben Smith's


[Edited on 12/8/05 by stevebubs]

FWIW, I used nothing more complex than:

Screwdriver
Spanners
Hacksaw
Domestic Pipecutter for the fuel rail

So how did you do it then?

I'd like one for a 2L 8V VX engine....

Forgot that I borrowed a spot welder for 10minutes, but essentially...

• Unbolt and separate individual throttlebodies from each other
  
• Mount individual bodies onto dcoe manifold using gsxr flange mounts
  
• measure spacing between bodies and cut spacers to replace the old ones; 100mm bar with 6mm hole in the middle works well for this
  
• cut threaded studding to replace long bolt between bodies and bolt them up
  
• turn over and cut a piece of flat bar to provide additional bracing; drill bar for mounting holes already provided bodies
  
• cut another piece of flat bar approx the same length as the bodies
  
• mount jenvey fuel rail onto flat bar, getting spacing from injector mounts on bodies
  
• fit injectors into bodies, trial fit fuel rail and measure length of spacer required for mounting bolts
  
• make spaces, drill mounting holes in rail flar bar
  
• fit injectors and rail
  
• get some small pieces of 2mm steel
  
• get friend / local college to spot weld them onto the existing linkage
  
• fit completed assembly to your engine
  

forgot to add

• cut link pipe for fuel rail. DO NOT USE HACKSAW AS THE SHARP EDGES WILL BUGGER UP THE "O" RINGS
  

One thing I have noticed recently, though is that, for zetec applications, the ST170 manifold looks like it could be used instead of the DCOE one - and I don't think you'd need the flanges,just use the airbox mounting rubbers or replace them with suitable sized fuel filler hose

This would also give you a second set of injector mountings and fuel rail, which means you could just bung up the ones on the gixxer bodies and reserve them for higher flow ones when you fit the turbo as you're only really using them for the butterfly assembly (which means you *Could* just use a knackered set of dcoes!!!)

HTH

Stephen

[Edited on 12/8/05 by stevebubs]

[Edited on 12/8/05 by stevebubs]

PPS The RAM pipes on my engine are 48mm jobbies from Merlin - about 30quid, and are attached using fuel filler hose

u have u2u