andrenel
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| posted on 15/11/07 at 04:34 PM |
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how to fabricate fuell rail for throttle bodies
General question about fuelling.
On the gsxr 600 bodies that I have there does not appear to be space for a return line to the tank, also once I have split the bodies into two
sections to try and equalise the spacing, can one still utilise the existing rail in sOme way? or any ideas on fabricating a replacment one
Does anybody know what the recomended injector's would be as I believe the existing 600 ones are only 190 cc/min .I believe I should be looking
at somewhere around 240 --> 300 for a 2l zetec. something that would fit straight into the injector holes on my bodys ( will the ford ones fit)
and could I cannabalize the ford rail ?
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paulf
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| posted on 15/11/07 at 05:12 PM |
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The gsxr injectors are about 230cc and should be big enough for a standard tune engine, it is possible to increase the fuel pressure for more flow by
using an adjustable pressure reg.
It is not possible to use the ford injectors as they are side feed injectors and require using with the original ford fuel rail which is to bulky to
fit to the throttle bodys.
I made a fuel rail from some 10mm id steel tube with bosses reamed 11mm to fit the injector o rings and retained with a couple of screws into the
original fuel rail mounting points.
Paul.
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Ricks-9r
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| posted on 15/11/07 at 06:07 PM |
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Re- Fuel Rail
http://www.locostbuilders.co.uk/viewthread.php?tid=77675
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andrenel
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| posted on 15/11/07 at 08:17 PM |
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that rail material looks like interesting stuff, any idea on a local supplier, or do you have any left?
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rf900rush
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| posted on 15/11/07 at 09:42 PM |
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Hi
The most common size injectors I found listed on the WEB for the GSXR600 TB'S was 240cc.
I made my own fuel rail using the above type of extrusion.
From memory I think I got mine from here
linky
Each end will need some sort of fitting.
It was not easy make the Injector holes.
As for the return I did not need one. Using the GSXR600 setup dosn't need one. I used the bike's in tank Pump/regulator assmembly.
Using a simular power Bike engine made things easier.
I have some pictures on my Web pages.
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Jenko
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| posted on 16/11/07 at 10:04 AM |
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I'm currently doing a Megasquirt conversion using the GSXR600 TB's - Assuming you are using the K1-K3 TB's, then I don't think
splitting the current fuel is going to be an easy task...If you are spacing all 4 TB's, then you will need to cut the fuel rail in 4 parts,
redrill the ends as they are only single feed, then work out a way of clamping the fuel rail down.....I think the better way is to make up a new
rail.....
Unless I'm missing something, the actual hole for the injectors does not look to difficult.......My plan is a 7mm hole all the way through to
the fuel way, then drill the same hole out (but not as deep) to the 10.8mm that the injectors measure....The GSXR rail has a chamfer at the top, but I
can't work out why...So I think this will not be needed.
Anyway, will keep posted on progress....
PJ.
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matt_claydon
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| posted on 16/11/07 at 07:10 PM |
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On my GSXR bodies I just cut the joiners between the injectors and rejoined with fuel hise and jubilee clips. I bought a second inlet from suzuki for
silly money but there are other way around that.
See bottom pic here: http://locostbuilders.co.uk/viewthread.php?tid=49209
[Edited on 16/11/07 by matt_claydon]
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paulf
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| posted on 16/11/07 at 10:42 PM |
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The hole needs to be reamed ideally to give the correct finish and size for the O rings , the correct diameter is 11mm.
Paul.
quote:
Originally posted by Jenko
My plan is a 7mm hole all the way through to the fuel way, then drill the same hole out (but not as deep) to the 10.8mm that the injectors
measure....The GSXR rail has a chamfer at the top, but I can't work out why...So I think this will not be needed.
Anyway, will keep posted on progress....
PJ.
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Jenko
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| posted on 17/11/07 at 07:10 AM |
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Matt, The GSXR 600 fuel rail is totally different to the 750....It's a single cast item that cannot be spaced without welding...I think many
people have ended up buying a 750 rail like yours....
Paul, I've measure mine with a vernier to 10.89mm, however, I do notice there is a slight difference between them.......But I agree reaming
would be better, I'll keep you posted on my home made rail.....Not looking forward to that bit!.........
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andrenel
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| posted on 17/11/07 at 12:50 PM |
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Ok i have managd to get some pictures of mu bodies in my photo archieve.
mine split into two pieces
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andrenel
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| posted on 21/11/07 at 02:12 PM |
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split
Picture of the spaced bodies with runners ready to be weleded to manifold plate.
Used extended nuts to space the bodies by 1 inch, almost a perfect fit.
Did the same to the connector that came with the fuel rail .
I am going to use a tea piece pressurised fuel in , one tea to the rail and then put a regulator and gauge on the return line side of tea
 
Rescued attachment PICT0024s.JPG
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matt_claydon
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| posted on 21/11/07 at 02:38 PM |
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That is a fine way to do it when your rail has only one inlet, but personally I would go for this layout with the tee:
H/P inlet
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|---- To regulator/return
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To fuel rail
You tehn have the most direct path to the injectors and will suffer less pressure drop. The difference may be marginal but you might as well.
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