I am having another go tomorrow at making an inlet manifold to match zetec to r1 tb's.

And, of course, I have a couple of questions:

1. Is there some sort of metal filler that I can use to fill bends in the manifold tubes and therefore smooth the flow to the engine?

2. What is the best way to smooth the inside of the manifold tubes?
I currently have some sort of drill attachment that is meant to grind metal, but seems to struggle with anything that is not ali.
Are the cutting discs for the dremel any good?

Lars

You could do worse than visit www.guycroft.com - he has been tuning and modifying engines (incl. F1's) for years and there's lots of useful info. on there.
Cheers, Pewe

Coozer's is one of the best I've seen..

For my ZX6R carbs I've used the bike carb rubbers attached to a manifold plate bolted to the head.

The manifold length is shorter than is ideal, but it works [so far] and is easy / cheap to do.

For mine it cost £20 to make.

I'm sure you could do the same with TBs.

Stu

[Edited on 19/3/08 by whitestu]

[Edited on 19/3/08 by whitestu]

How about buying an ST170 manifold? Got to be just as cheap and far easier!

The R1 TB's will fit straight on. You can also then use twin injectors if you wanted too!

Wyn

I have already bought an inlet manifold plate and some 2" pipe which is the same diameter as the R1 TBs. (and i have the rubbers as well).

The problem is that I need some sort of funnel to make this fit to the manifold plate, as the 2" pipe is much larger than the zetec inlet.

I will therefore have to weld something up, which will need smoothing afterwards. (If that makes sense)


Wyn, I did have a look for ST170 manifolds a while ago, but could not find anything cheap.

Lars

Hi have a look in my photos under zx9r carbs and manifold

[Edited on 19/3/08 by jacko]

Jacko

So can I use brazing as a way to smooth/fill the pipe bends?

Did the rotary file work well?

Lars

it is a steel manifold you are making ?
yes you can braze it that is what i did .
The rotory file worked well + i used a round sanding wheel to finish off
Graham

I have got a mild steel plate, but stainless 2" tubes.

I don't know anything about brazing, can I just get some fluxed rods and use these with my handheld torch? (as I am not using it for any structural joints)

Yes but i dont know how good braze will be on stainless steel

I shall test it tomorrow.

Thanks for your help.

Just done a google and found a web
BT brazing & welding 304l s/ steel have a read it may help you

found the website.

Sounds like I should have stuck with mild steel.

I'll see what I can find instore tomorrow.

If you are thinking about using brass/bronze filler rods you won't get far trying to braze with a standard blow lamp. You really need something a fair bit hotter (preferably oxy-acetylene).

I managed to do some silver soldering with my blow lamp, but it was only just hot enough.

Lars - people have realised that there is a market for ST170 manifolds with us 'kit' builders so prices are bumped up immediately!

I bought mine from the States - link

THere's one on eBay here but pricey!

Best of luck!

Regards

Wyn

Wyn

How sure are you that the R1 TBs will bolt straight on?
The pipe looks a little small, I need these to be 2".
Also, it may just be the pictures, but it doesn't look like the outside tubes on the manifold converge enough for the TBs.

Lars

Why use something as hard as braze? plumbers solder or lead will be fine, it will never get hot enough to melt it.

Both these have the advantage that with a bit of tallow on leather you can smooth over while in a plastic state, just mind those pinkies.

If you want convincing, how many cars have plastic manifolds these days, I bet you can melt a ball of solder through these with ease.

Some of the tuning books I have also talk about using expoxy resin.

Regards Mark

I was thinking about that today while in browsing brazing rods.

I was not worried about temperature, but was not sure how these put up with fuel.
Would fuel cause any problems?

Lars

I've tried my R1 TB's roughly and they seem about right They will need spacing out but you won't need to worry about a fuel rail (the difficult bit of spacing) as you can use the ST injectors and rail.

I'll try them again tomorrow to check sizes etc.

Wyn

my TBs cannot be spaced, I would need to cut them apart.

Maybe I should have gone for the GSXR ones after all.

quote:

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my TBs cannot be spaced, I would need to cut them apart.

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Mine are from a 2005, and are split into 2 pairs. (like the weber 40,45, etc)

Individual ones would definitely seem easier.

mine are in pairs as well, I just made a spacer out of aluminium on my lathe.

still have to figure out the linkage between them though.

I had my plate cut on a cnc mill, and I'm cutting the runners on the lathe, and then squishing the ends in a vise. its all being done in Aluminium.

Lars

I'm looking for a pair of 5VY throttle bodies for my spare engine. You could sell them to me and buy a set of individual bodies (5PW?).

Regards

Wyn

almost done my manifold, gotta fabricate the last runner then get it welded