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Old 30-06-2008, 07:16 AM   #1
sandy309
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Our new GSXR inlet manifolds

Me and Colin were asked a few months ago (or was it years?), to make versions of my TU inlet designs for GSXR 1000 bodies onto both the 8v and 16v. I admit to not previously being that impressed by bike bodies, because of the fitting issues. But the more we looked into it, it became clear that a fresh approach could solve most of the limitations of fitting bike TBs and take advantage of the low cost and (generally excellent) quality of most bike TBs.
The main one is to get a tract shape that I'm happy with and Colin sorted out a flange design for the outer end of the manifold that does away with the traditional hose connections for the bodies, in favour of a solid flange. There are numerous advantages to this, but the main one I was interested in, was getting the best tract shape possible. I'm satisfied now that it's as good as any set up can be, DTH or otherwise!
The next big issue is throttle control. I've seen alot of people writing about the plate angle, but I don't think that's the issue, it's more about the quadrant design. So I badgered Colin into making bespoke quadrants to solve this.
Trumpets (other than the bike ones) are notoriously difficult to fit properly. Colin's making some modular trumpets that will not only fit perfectly, but also allow me to tune the tract length quite easily, which is in my experience, highly effective in getting the best results, not just in terms of power, but driveability and side effects.
The fuel rail is still being resolved, the intention being to retain the GSXR rail and make it suitable for bosch/weber injectors for maximum versatility.
The end result will be a package rather than just a manifold. The idea being that Colin will assemble the kit with the supplied TBs and make it ready to fit.

Here are the pics of the trial fit on our fabulous S1:
8 Valve for the hardcore....


16 Valve for the others.....
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Old 30-06-2008, 08:20 AM   #2
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Sandy, I meant to ask you... do the manifolds use the the standard gsxr spacings or do you re-space the bodies to suit?

Also, do you remove the 2nd electronic butterfly or leave it in fully open position? if removed, how are the holes plugged?

Also, I notice there's a vacuum take off on the manifold... what happens with the vacuum holes in the bodies?

My bodies came with all the ancillaries so it would be cool to use the fuel rail. Nice one both for developing it, makes TB'ing more affordable for people!

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Old 30-06-2008, 12:24 PM   #3
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Excelent

Quote:
Originally Posted by hank_marvinson View Post
Also, do you remove the 2nd electronic butterfly or leave it in fully open position? if removed, how are the holes plugged?
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Old 30-06-2008, 04:52 PM   #4
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saw colin makign these and a finished one on saturday they do look very good
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Old 30-06-2008, 04:53 PM   #5
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excelent Sandy!
Any idea on expected prices for the package?
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Old 30-06-2008, 05:30 PM   #6
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prices prices prices! very interested in a 16v manifold/kit if it is affordable.
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Old 30-06-2008, 05:40 PM   #7
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same as above
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Old 30-06-2008, 08:58 PM   #8
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Sabdy sounds interesting! Wouldnt mind doing a back to back on my engine with 45 bodies and these babies! i will have top pop down for a day! Be some interesting results i think!

P.S She is still going strong!
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Old 30-06-2008, 09:27 PM   #9
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sweet !! look amazing sandy !! but i didnt expect anything less !!

ill be putting my tb's (and pistons) in the post this week sometime mate !! so expect a package !!
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Old 30-06-2008, 09:36 PM   #10
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Originally Posted by tommy_a View Post
ill be putting my tb's (and pistons) in the post this week sometime mate !! so expect a package !!
i will also be putting my tb's and pistons in the post to you this week so don't mix them up!!!
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Old 30-06-2008, 10:14 PM   #11
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16v all the way
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Old 30-06-2008, 10:27 PM   #12
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What bodies are they, the ones I supplied?
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Old 30-06-2008, 10:51 PM   #13
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well i must say sandy since our discussions at the end of last year ive been saving like a squirrell, any idea on rough time scale on how long the kits will be untill available?
and of course the biggie, price?

awesome work as allways
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Old 01-07-2008, 06:01 AM   #14
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Quote:
Originally Posted by hank_marvinson View Post
i will also be putting my tb's and pistons in the post to you this week so don't mix them up!!!
No problem Miles

The outer throttle plates are removed and a tapered sleeve fitted that covers the holes and provides the tract shape I want. The trumpets attach to that.
It'll keep the bodies spacing, close enough to the port spacing not to be an issue, better than DCOE on the 8v!
The kits should be available within about 2 weeks. We have several people already ordered, so they will be done first obviously.

Colin reckons the "kit":
Inlet manifold
TB brackets onto manifold and sealing rings
Revised throttle quadrant
Cable bracket
Injector position revisions
Trumpet sleeve flanges and trumpets
Assembly of customer supplied bodies into the kit
About £450 inc VAT

It's alot more than just buying an XXXX manifold obviously, but it's a ready to fit set up, design to perform as well as possible, rather than just cobbling it on.
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Old 01-07-2008, 08:31 AM   #15
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Wow! nice work Sandy. I'm spoiled for choice now as Benji is working on a kit too. You guys are like buses, wait for one then two come along! lol
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Old 01-07-2008, 01:45 PM   #16
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Great Sandy!!!!

you made the angle 30 degrees? To get the trumpets at the right place through the bulkhead?
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Old 01-07-2008, 04:49 PM   #17
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looks very nice sandy

When will the first 16v be rolling roaded using these? any pics of the trumpets?
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Old 01-07-2008, 05:01 PM   #18
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Can't wait for these to be done.

I'll deffo be after the set up
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Old 01-07-2008, 06:22 PM   #19
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It looks like the first 16v will be SaxoRo's. (QEP head, PT52s etc). The first 8v will be James' minter XSi.

God knows what the angle is Henk, we make jig them mostly by eye!
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Old 01-07-2008, 06:35 PM   #20
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i think i will be watching this thread with a close eye!!!!

Ben
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Old 01-07-2008, 07:09 PM   #21
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Sandy, this looks very exciting indeed. Looks very craftsmanlike as ever; good to see a price to go with it as well! The bit I'm interested in is the consequential expenditure. You're looking at new management to go with this aren't you? Anything else?
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Old 02-07-2008, 02:37 PM   #22
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Is there any removing of sheet metal or re-postioning of components in regards to clearance issues needed to get the set-up fitted?
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Old 02-07-2008, 06:42 PM   #23
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Sandy this keep looks very nice indeed! Which GSXR T/B's are needed, I believe there are a few variations?
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Old 02-07-2008, 07:13 PM   #24
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i'm in the line for one of these, will i be able to mount this kit myself? would be somewhat timesaving if i didnt have to ship it from norway to uk and then back again...
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Old 02-07-2008, 07:27 PM   #25
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can u not get some bodies off ebay and get them posted to sandys address? thats if you havnt already got them of course.
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Old 02-07-2008, 07:42 PM   #26
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Quote:
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can u not get some bodies off ebay and get them posted to sandys address? thats if you havnt already got them of course.
already got them nicely placed infront of my tv
well, they were..sent them to a friend who works at Suzuki to see if he could find some proper injectors, but seems as that wont be an issue now
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Old 02-07-2008, 10:30 PM   #27
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Sandy this keep looks very nice indeed! Which GSXR T/B's are needed, I believe there are a few variations?
The ones I gave him and Colin are GSXR1000 K1/2 (2001-2002) model. They taper 48mm to 42mm IIRC. Newer ones are paired together so may have different spacing and are a different bore.
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Old 03-07-2008, 05:24 AM   #28
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Exactly what James says. Although we're also looking into doing an alternative version for a less popular set of bodies, in case the price of these goes up too much.

We could send a kit to Norway if you wish.
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Old 03-07-2008, 06:36 AM   #29
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Quote:
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We could send a kit to Norway if you wish.

already spoke to colin, so i'm in the que already but will there be any problems mounting this kit myself?
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Old 03-07-2008, 07:42 AM   #30
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As long as you're reasonably able, you'll be fine!I'll try a write a mini guide which I'll post here.
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Old 03-07-2008, 08:15 AM   #31
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Very nice!

You could also try using Honda ITB which are cheaper (but a little). They are much lighter but you can only separate them in couples. Especially for 8V the CBR 600 series with 40mm on the butterfly are a good fit.
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Old 03-07-2008, 08:41 AM   #32
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Sandy are the injectors left in the standard position? Can this kit be used with a dual injector setup?
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Old 03-07-2008, 11:10 AM   #33
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On the 8v you could easily run two sets yes. On the 16v, it would require a set of bosses to be made into the tracts, do-able of course.
Colin is making the bodies injector position suitable for regular Bosch/Weber injectors.
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Old 03-07-2008, 11:27 AM   #34
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I'm going to have to save all my cash now, the suspensions almost done and I'll be speccing an engine and box next for the engine bay restoration and Sandy has put a hell of a lot of ideas into my head... Might have to holiday in Cornwall for a week or so....
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Old 03-07-2008, 11:56 AM   #35
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Haha, I reckon Colin and I should get a kickback from the local B&Bs
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Old 03-07-2008, 02:51 PM   #36
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Sandy I see the price includes assembly with the customers bodies.

If you were just to supply everything and not carry out assembly, how much would you charge for all the parts?
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Old 03-07-2008, 02:53 PM   #37
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Haha, I reckon Colin and I should get a kickback from the local B&Bs
I can just see the stickers on the B&B's door "powered by Sandy Brown"

Is it just the GSXR 1000 TB's that are the RR approved version? Or are the 600 or 750 the same?
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Old 03-07-2008, 04:17 PM   #38
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The K1-3 GSXR750 and 1000 bodies are idenical.
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Old 03-07-2008, 04:52 PM   #39
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what injectors are used on a standard 16v? bosch ones? as i fitted these to my gsxr bodies no problem. straight in.
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Old 03-07-2008, 05:44 PM   #40
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Standard 16v are Weber "Pico", which are shorter than normal Bosch ones.
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Old 08-07-2008, 05:35 PM   #41
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Any news good sir?
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Old 08-07-2008, 05:52 PM   #42
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Hopefully have one together by the end of the week, im buisy making the trumpets at the mo.
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Old 08-07-2008, 06:39 PM   #43
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Good stuff!
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Old 08-07-2008, 06:42 PM   #44
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what length trumpets are you making mate? and a rough price would be nice
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Old 08-07-2008, 06:52 PM   #45
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adjustable length ones
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Old 09-07-2008, 11:36 AM   #46
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Old 09-07-2008, 09:12 PM   #47
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Will the GSXR750 42mm Bodies fit onto this manifold? As there suppose to be the same as the Suzuki GSXR100 k1/k2 bodies?
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Old 10-07-2008, 07:42 AM   #48
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Will the GSXR750 42mm Bodies fit onto this manifold? As there suppose to be the same as the Suzuki GSXR100 k1/k2 bodies?
I'd say YES!

I have one set of these and 2 sets of the GSXR 1000 K1-K2 and they are the same
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Old 10-07-2008, 09:52 AM   #49
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pm'd really interested in this lol after speaking to drive thru on 106oc last night and looking at ebay
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Old 11-07-2008, 07:09 AM   #50
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Colin's finished the billet trumpets, note that a filter backplate can be bolted onto the back of the trumpet mouth, he's made two trumpet lengths, one for uncut scuttle and one for the airsaw enthusiasts. We could make any length if required at nominal extra cost:





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