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 Post subject: DIY ITBs
PostPosted: Mon Jan 23, 2012 9:33 am 
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Location: blue mountains
OK so I seeing as I've had a few PMs about my ITBs I thought I'd put together a DIY to answer some of the questions.

To start with I sourced some K1 GSXR 1000 throttle bodies from the US like this:

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I wanted K1/K2 because the individual TBs could be sperated. Cost about $200 delivered.
I then seperated them and removed the secondary butterfiles, TPS, injectors etc, leaving the primary butterflies and linkages.

Image

I filled in the holes from the secondary butterflies with epoxy putty. Then I used some small alloy tube in place of the injectors as a vaccum point for the brake booster.

Using Striders intake flange as a guide I spaced the TBs to suit. I bought some threaded rod and spaced the TBs using nuts as required. Then dome nuts on one end, lock nuts on the other and tighten everything up. The linkages were simply bent to work with the spacing. As I would be running an aftermarket ECU I just used the GSXR TPS.

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Next was the manifold. I wanted to have short, angled runners so that I would have enough clearance on top to fit cone filters. It was a bit tricky getting the angle right as I had to clear both the brake booster and fuel rail. I made a cardboard template and attached it to the flange, then assembled it for a trial fit.

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When I was confident I had the template right I had short alloy madrel bends welded on. Ended up looking like this:

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The TBs were attached using hose and hose clamps.

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Next I had to modify the throttle cable and pedal to achieve the same pull ratio as stock. The OEM TB needs about 45mm of cable pull to fully open, the GSXR 25mm. I took the pedal off and after some quick measurements I decided to mount the new cable 80mm lower down on the pedal.

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I made a new throttle cable using a bike throttle kit and located it lower down on the firewall to suit the pedal.

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I bought some booster hose and T pieces to link up all the vac ports. Also bought some short velocity stacks to suit.

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Couple of photos of the finished product.

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I put some cone filters on for street use.

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It wasn't that hard to make, just fairly time consuming. Cost about $800 all up. I hope this has been helpful. Feel free to ask any questions.

Heaps more photos here.

Cheers

Tom

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 9:54 am 
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Very nice

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 2:29 pm 
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Location: Brisbane
Great post.

A few people have also used the stock manifold and cut it down to use it as a flange.

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 3:04 pm 
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papa wrote:
Great post.

A few people have also used the stock manifold and cut it down to use it as a flange.


Yes, but then your're stuck with oval ports/runners. Striders flange makes it much easier.

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 4:01 pm 
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Give you $500 for them :D :D
Have you had it tuned yet Tom? ( Finally fitted the swaybar I grabbed off you!)

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 4:39 pm 
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mlc2318 wrote:
Give you $500 for them :D :D
Have you had it tuned yet Tom? ( Finally fitted the swaybar I grabbed off you!)


Haha I think I'll keep them. I've been asked to make a few sets at $700 each but its just not worth the time it takes.

Yep all tuned up, 110hp. You got a rear sway bay yet?

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 8:19 pm 
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good info man 8) mine done by the engine builder. pretty happy with the result

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 8:24 pm 
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Email me some pics Strider.

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 8:40 pm 
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Yeah Tom, got one and had a big weekend, fitted new front and rear bars, new koni/coilovers, new cultus engine, all good till the front crank seal leaked :cry: but just about all fixed again!!

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 Post subject: Re: DIY ITBs
PostPosted: Mon Jan 23, 2012 10:07 pm 
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What ECU did you use with the quads? Was it easy to set up?

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 Post subject: Re: DIY ITBs
PostPosted: Tue Jan 24, 2012 7:39 am 
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[YLD80Y] wrote:
What ECU did you use with the quads? Was it easy to set up?


EMS Stinger. Easy enough to set up, just have to make sure you've got an accurate & consistant TPS.

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 Post subject: Re: DIY ITBs
PostPosted: Tue Jan 24, 2012 9:01 am 
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Excuse my ignorance, but without a plenum how does the ECU get a MAP/MAF reading?

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 Post subject: Re: DIY ITBs
PostPosted: Tue Jan 24, 2012 9:08 am 
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Tap in a vac line between the head and the butterflies. All linked together works fine for MAP. (I also run EMS Stinger with ITB's)

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 Post subject: Re: DIY ITBs
PostPosted: Tue Jan 24, 2012 9:18 am 
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tom-storm wrote:
papa wrote:
Great post.

A few people have also used the stock manifold and cut it down to use it as a flange.


Yes, but then your're stuck with oval ports/runners. Striders flange makes it much easier.


Not really you press bend then runners to match the ports or dremmel out the runners to match the head. Depends if you want to save money or not.

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 Post subject: Re: DIY ITBs
PostPosted: Tue Jan 24, 2012 9:43 am 
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[YLD80Y] wrote:
Excuse my ignorance, but without a plenum how does the ECU get a MAP/MAF reading?


I'm not using MAP sensor, I've set up the ECU to TPS only.

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 Post subject: Re: DIY ITBs
PostPosted: Tue Jan 24, 2012 10:24 am 
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papa wrote:
tom-storm wrote:
papa wrote:
Great post.

A few people have also used the stock manifold and cut it down to use it as a flange.


Yes, but then your're stuck with oval ports/runners. Striders flange makes it much easier.


Not really you press bend then runners to match the ports or dremmel out the runners to match the head. Depends if you want to save money or not.


Yes, and I was going to do it that way until I saw Striders flange. I think its a much neater and easier way of doing it, therefore worth the money.

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 Post subject: Re: DIY ITBs
PostPosted: Tue Jan 24, 2012 7:34 pm 
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have to say i just opened my package from strider which i bought a flange plate and its excellant.

You itbs looks very smick too. Very clean. Im looking to go to remote resiviour BMC so i have a little more room. I also have a strut bar with engine steady and hope to go below it.

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 Post subject: Re: DIY ITBs
PostPosted: Tue Oct 23, 2012 4:26 am 
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how can this be done with out a full new ecu?? i want to just use a chipped one


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 Post subject: Re: DIY ITBs
PostPosted: Tue Oct 23, 2012 6:10 am 
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eoinl4529 wrote:
how can this be done with out a full new ecu?? i want to just use a chipped one

Plenum and afm. And then the tune in the chipped ecu would be totally wrong and it would run like a bag of s**t. :roll:

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 Post subject: Re: DIY ITBs
PostPosted: Fri Oct 26, 2012 5:10 am 
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where do i get the flange to buy and for how much??

thanks


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