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 Post subject: How to make your own quad throttle setup
PostPosted: Sun Dec 01, 2013 10:18 am 
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Location: BRISBANE
I know there is a few different versions of these but this way I designed mine
Part #1
2002 gsxr1000 quad throttles
$200 (ebay)
Part #2
Custom aluminium intake flange
$190 (strider here on redline)
viewtopic.php?f=3&t=48587&hilit=itb+flange
Part #3
4 45 degree aluminium pipe bends 50mm diameter 3m thick pipe
$60 ( http://www.tubebendonline.com/ )
Part #4
4 itb stacks
$100 ( pcp01 here on redline )
Part #5
Unifilter socks 100mm tall 75mm internal diameter with spring to retain sock structure
$70 ( http://www.uniflow.com.au/ )
Part #6 (to make brake booster vacuum see picture below)
threaded fittings from pirtek
4 brass threaded fittings
3 t piece pneumatic pvc snap in fittings
1 45 degree piece pvc snap in fitting
1 metre of pvc airline to suit the above fittings
Approx $80
Part #7
4 silicone sleeves with 4 clamps to hold sleeve to itb
( the sleeves I got were tight enough to hold the stacks by themselves)

Later through the week I will post a picture for each part and specific info for the process of making them. Which will be edited many many times to make it easy to understand.

First picture is the end result.


Attachments:
qtb3.JPG
qtb3.JPG [ 751.83 KiB | Viewed 303 times ]

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with GSXR 1000 QUAD TB'S


Last edited by 1600GTI on Mon Dec 02, 2013 10:17 pm, edited 3 times in total.
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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Mon Dec 02, 2013 12:12 pm 
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Location: Melbourne
schweeter than easter time with the kids! :D great tech thread


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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Mon Dec 02, 2013 2:22 pm 
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Location: Brisbane
Thanks for taking the time to post and share the info. =D> =D>

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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Mon Dec 02, 2013 3:43 pm 
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And it's been linked in the Technical FAQ.


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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Mon Dec 02, 2013 8:17 pm 
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Location: BRISBANE
Part #1
2002 gsxr 1000 quad throttle bodies

If you make the quads the way I have designed them then you should be able to get away with pretty much any gsxr efi quad throttle bodies.
2002 model has been suggested if you prefer to separate and space the tb's out to match the intake porting and manifold flange. If you follow my steps you will avoid this hassle.

Remove the Injector rail and injectors.

Remove the secondary butterflies the rod and the motor that controls them. Leave the tb spacers on. Silicone the two outer holes off. Do not remove the rail and butterflies that attach to the tps and throttle cable setup. Keep the vacuum lines as these are suitable to connect to your ecu.


Attachments:
11.JPG
11.JPG [ 1.03 MiB | Viewed 293 times ]

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1600/1300 TWINCAM BALENO
with GSXR 1000 QUAD TB'S
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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Mon Dec 02, 2013 10:00 pm 
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Location: BRISBANE
Part #2 option 1

Striders intake flange (his last batch is on sale now, no more reproduction)
Once striders flanges run out, I am willing to cnc machine these at my work if there is interest.

These are ready to rock and roll bar one issue I encountered. You need to die grind the area where the injectors have been cnc machined. Seems to have only been cnc'd enough for a skinny injector. Recommend doing a dummy fit until you have adequately ground enough off. You will be surprised how much I had to die grind off.

Other option is to make your own flange from mild steel. Cons are that it is heavier and you need to coat it with something to stop it from rusting.

Tip: call your local auto parts store and get yourself a new intake manifold gasket. You are kidding yourself if you think you can reuse your original. I know suzi auto services springwood stock them.


Attachments:
flange.jpg
flange.jpg [ 45.92 KiB | Viewed 5899 times ]

_________________
1600/1300 TWINCAM BALENO
with GSXR 1000 QUAD TB'S


Last edited by 1600GTI on Mon Dec 02, 2013 10:15 pm, edited 1 time in total.
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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Mon Dec 02, 2013 10:12 pm 
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Location: BRISBANE
Part #2 option 2

I actually made this one but I am very picky and I wasn't happy with the outcome.
Mild steel with protective coating

I wont dive too deep into this option.
Its basic, laser cut steel flange exactly the same as standard cast one.
4 45 degree mild steel bends, you need to pinch one end into an oval shape to suit intake porting and weld. These ones are lined up ready to fit gsxr 1000 quads without having to separate each throttle body. Goodluck it's not easy LOL.

If anyone likes this idea I have this one for sale $50 plus postage


Attachments:
mildsteel.JPG
mildsteel.JPG [ 1.1 MiB | Viewed 276 times ]

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1600/1300 TWINCAM BALENO
with GSXR 1000 QUAD TB'S
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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Mon Dec 09, 2013 7:23 pm 
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Part # 3

45 degree aluminium tubes 50mm outside diameter 3m thick pipe

They will come with approx 300mm straights on each end, you will need to dock the pipes to suit the runner length you require. I suggest you dummy fit these to ensure maximum length possible but keep in mind you need to clear the brake booster in a gti setup.

As you can see in the picture I pitched the two outer pipes inwards to match the standard spacing on the gsxr tb's to save the hassle of separating them.


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pipe.JPG
pipe.JPG [ 562.64 KiB | Viewed 265 times ]

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1600/1300 TWINCAM BALENO
with GSXR 1000 QUAD TB'S
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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Fri Jan 03, 2014 9:52 am 
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very well engineered.

Well done on build cant wait to see how you go getting them on the car.

Why did you weld the TB to the manifold rather than using silicone joiners or similar? Are the TB still serviceable?

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 Post subject: Re: How to make your own quad throttle setup
PostPosted: Sat Jan 04, 2014 3:59 pm 
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Location: BRISBANE
Thanks SOBIL.
I don't really like the look/idea of the silicone sleeves.
When I get it up and running , I will test long and short stacks and once I find a length I am happy with I will weld the stacks on too.
Yes it is all still serviceable.
And will still be after I weld the stacks on too. :)

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1600/1300 TWINCAM BALENO
with GSXR 1000 QUAD TB'S


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