blockhead_rich
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 posted on 27/2/06 at 09:09 PM |
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Yipeee...GSXr onto a 4AGE
From this;
 
Inlet manifold for GSXr 600 T/
To this;
 
Inlet manifold # 2
and this;
 
Inlet manifold # 5
I'm happy with the result anyway!!
Rich
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mookaloid
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| posted on 27/2/06 at 09:11 PM |
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It has to be said - that is very impressive
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big_wasa
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| posted on 27/2/06 at 09:13 PM |
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Come on then spill the beans. That looks the B*ll*xs.
what sort of casting method ? Lost wax ? How did you get it cast ? What alloy ?
I want to know lots more please.
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Chazzy
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| posted on 27/2/06 at 09:51 PM |
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looks fantastic, all the same questions as above, plus, how much (ish) can you do others?
toying with the idea of changing the dellortos to throttle bods, more than a little work i know, but having that part sorted saves fabricating a la
practical perfromance car.
Chas
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BKLOCO
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| posted on 27/2/06 at 09:56 PM |
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Nice one Rich
You've got to Megasquirt it now...Be bloody rude not to...
Experience is what you get when you don't get what you want!!! 
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olv
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| posted on 27/2/06 at 10:55 PM |
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Looks fantastic. What model GSXR are the throttle bodies from?
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blockhead_rich
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| posted on 27/2/06 at 10:56 PM |
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Right folks
More pic's in my archieve..
Got my man @ work to do the CAD modelling for me (just followed my instructions)....then after a couple of rapid prototypes came up with a final
design. This was then cast by a mate I play footie with (it also helps that the Technical director and MD and Sales Manager all play as well).
Unfortunatly the lovely prototype was lost in the casting process.
Wait a few weeks then... Bingo - I was like a kid in a sweat shop when I picked it up... I didn't expect the quality to be so good.
Now for the Megasquirt....
Oh, I'd need plenty of deposits to make it worth my while creating a casting former.
But you never know...U2U me with serious enquiries and I'll go from there. I'll ask my mate what the casting cost would be and what sort
of cost a former would be too.
By the way casting Co was Noaks foundry, in Halstead Essex....recommended!!!
Rich
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blockhead_rich
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| posted on 27/2/06 at 11:00 PM |
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I think the Throttle bodies are from a 600 but not 100% sure, inside dia are about 40mm.
Just in the process of making my ram pipes too.
Rich
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Ben Smith
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| posted on 27/2/06 at 11:14 PM |
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Looks great. I put 600 gsxr t/b's on my 4age last year. It worked really well, the 600's are the perfect size for this engine. With
uprated cams it made 161bhp and would happily rev to 8000rpm all day. Just finishing putting an r1 in it now. looking forward to seeing how it
compares. There are a couple of photo's of gsxr conversion in my archive.
Ben.
PS. Just looking at your archive and noticed your engine mounts are very similar to the ones I had on the striker. These had a habit of cracking the
vertical weld (4 times in total!). To over come this I put a vertical brace in that ran up the centre of the bolts. Didn't have a problem after
that.
[Edited on 27/2/06 by Ben Smith]
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liam.mccaffrey
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| posted on 27/2/06 at 11:23 PM |
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good work rich awesome looking!
are they the ones you bought from me?
if they are they are definately gsxr 600s, i think K2's or something. they originally had the auxilliary butterflies didn't they
Build Blog
Build Photo Album
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eddymcclements
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| posted on 27/2/06 at 11:26 PM |
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Rich - that looks suitable for a large-port 4AGE (ex-TVIS model)...am I right? If so I'd be very interested in a manifold to take bike TBs. Does
the manifold slant upwards from the head as it appears to do in the photos? I'll need that in order to clear chassis rails and steering column
(my engine is low and set weel back in the engine bay).
Cheers,
Eddy
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blockhead_rich
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| posted on 28/2/06 at 06:15 AM |
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Hi Liam, yeh, the T/B's were from your good self!
Ben
Thanks for the tip re engine mounts. Have you got a piccture of your mod at all?
Where did you get your cams from - RAW? Did you fit a steel head gasket too?
Eddy
Manifold slants upwards as you suggested - can't remember the angle off the top of my head. The cost of a one off casting is far more than
getting a manifold fabricated - my prototype should have cost £80.00 in material alone, and I'd hate to think what the a one off casting wold
have been - It pays to have good mates and an understanding boss! Casting mainfolds would only make sense if the volume was high enough to cover
these costs. I'll get my calculator out.
My thinking is that there are loads of parts that could be produced in this method though, especially lowered sumps and the like....ideas please.
Rich
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Ben Smith
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| posted on 28/2/06 at 10:28 AM |
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I haven't got the engine anymore so haven't got any pictures of that. It was simply a traingle of steel plate welded vetically between the
mounting bolts. A little smaller on the side with only 3 bolts. It's worth doing because you'll soon get fed up with taking them out to
fix them.
Yes the cams were from RAW and we fitted a steel head gasket. It was also a phase 3 engine. Hope this helps.
Ben.
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phongshader
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| posted on 7/3/06 at 10:59 PM |
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when modeling the prototype did you have to figure in shrinkage of the casting coming out of the mold? I here it's about 2-5%. Is this correct?
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chasmon
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| posted on 7/3/06 at 11:10 PM |
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With a master such as your casting you could manufacture high temperature resin replicas by vacuum casting.
Process costs (time not included) would be about £60 in silicone for a mould that will do 30 or so resin models. Resin c cost I'm not sure of
but it should be reaonable...
beleive it or not a non metal manifold is better as it will not suffer heat soak keeping the inducted air cooler and the volumetric efficiency up.
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garyo
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| posted on 8/3/06 at 08:14 PM |
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Hi Rich,
Where did you get the white trumpet/bellmouth from?
Cheers
Gary
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blockhead_rich
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| posted on 8/3/06 at 09:07 PM |
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Right, catching up here...
The shrinkage was factored in but for the life of me I can't remember the %, might have been about 1% but I can always find out if really
needed. Can out spot on I know!
I've got one prototype left but this does not have the shrinkage if that's any good to anyone. It's a bit brittle though.
Chasmon, can you make these resin parts then? What materials do you think would be strong enough? Could you use my spare prorotype as a pattern?
Bell mouths were again modelled up and rapid prototyped (based upon the GSXr's), so I've only got 4 (I've got 2 sets of the
GSXr's if any one is interested in these.
Rich
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MikeRJ
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| posted on 8/3/06 at 10:23 PM |
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Fantastic work, very professional looking. Could I ask why you have blanked the injector bosses off?
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blockhead_rich
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| posted on 8/3/06 at 10:52 PM |
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As I'm retaining use of the Toyota fuel rail and injectors.
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MrSandMan
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| posted on 9/3/06 at 12:21 AM |
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Let me know how much
quote:
I've got 2 sets of the GSXr's if any one is interested in these.
Rich
Rich I am trying to get some ram pipes for my R1 carbs. Let me know a price and some dimensions as I may be interested.
Ta.
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chasmon
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| posted on 9/3/06 at 05:20 PM |
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quote:
Originally posted by blockhead_rich
Right, catching up here...
The shrinkage was factored in but for the life of me I can't remember the %, might have been about 1% but I can always find out if really
needed. Can out spot on I know!
I've got one prototype left but this does not have the shrinkage if that's any good to anyone. It's a bit brittle though.
Chasmon, can you make these resin parts then? What materials do you think would be strong enough? Could you use my spare prorotype as a pattern?
Bell mouths were again modelled up and rapid prototyped (based upon the GSXr's), so I've only got 4 (I've got 2 sets of the
GSXr's if any one is interested in these.
Rich
I have experience of the process at work and we have the kit, however I would not do a homer like this though.
To be honest I'd be keener if you had a prototype for a Zetec :p It may be worth your while finding out how much a vacuum casting company would
charge. I'm guesing their labour costs (its intensive) would be the major cost...
Calling for anyone with access to vacuum casting kit!
I can find out what material would be suitable though for you.
[Edited on 9/3/06 by chasmon]
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phongshader
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| posted on 17/3/06 at 02:39 AM |
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That would be great if you could give me the shrink % I'm planning on doing something similar with a Duratec 2.3.
Thanks
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blockhead_rich
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| posted on 17/3/06 at 11:07 PM |
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Give me a few days and I'll ask my mate who did the casting - still can't remember the shrinkage % value. 
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phongshader
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| posted on 4/5/06 at 06:28 PM |
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Any luck on figuring out what the rate of shrinkage was?
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blockhead_rich
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| posted on 5/5/06 at 06:18 AM |
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The shrinkage was 1% but you would need to check this figure with the casting Company as it could vary depending upon process and material used I
think.
Rich
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