I dont think I've ever posted in this forum, but I figure some of you may get a kick out of this little project I've been working on. After doing tons of custom turbo setups throughout the years, I wanted to try something different.

here we go!



Starting off with a set of 2001 Suzuki GSX-R Throttle bodies. I picked up this set on ebay for very cheap! 50 bucks. The spacing looked about right, I think it was about 80mm, perfect for alignment on the B-series head.

Measureing at 42mm @ the butterflys and tapers to a 45mm (which also had secondary butterflys that were taken out).



The stock manifold was chopped off slightly after the fuel rail mounts, I then had 1 1/2 inch long aluminum runners welded on (1.75od) After the welded I had the manifold surfaced on both sides, and threw a chanfer on the lips of each runner. (75 dollars weld/machine work)



Here are the cheap *** velocity stacks I got on ebay, they were 35 bucks. used some small machine screws to fasten them down. Looks kinda cheezy, but they do the job.



These are the silicone couplers that attach the Throttle bodies to the intake manifold. Sounds kinda half *** huh? well the factory Suzuki ITB's are this way, and most other bikes too! And after attaching them they were very sturdy. I used Napa bulk Silicone hose, with some hose clamps.
(20 bucks from Napa)



The Cover shield that hides the linkage and other stuff, just cosmetic.



The factory ITB Fuel injector bungs were JB welded shut, except for the last one which has my brake booster port coming out. You can also see the map sensor signal lines, each port all T's into one and goes to the map sensor.




Thought it looked long? so did I, but after measureing up with the stock manifold, I felt a bit better, I thought for sure the stacks would be touching the firewall, but its actually just a bit shorter than the stock manifold.



The TPS situation, well the Suzuki tps had a way differant range than the stock honda one, I tried to make it work, but it just wasnt happening, So the stock honda one had to be modified to fit somehow.

First I made a baseplate with a hole saw and some scrap aluminum. This is on the backside of the shaft (driverside)

The Brass fitting, was bored out to be a custom bushing for the shaft.



The Shaft is actually a honda throttle body shaft cut down about 1/4



Now for mounting, I used a piece of PVC pipe to space out the tps, so it could mount solid.



Hoggered out the holes on the base plate a bit, so I could get a good amount of adjustment.



Used some extra long machine screws to mount it down



All mounted down, Its very secure and pretty easy to adjust.



Now setting the TPS up in the correct range. Stock TPS setting @ closed .4 - .5v



Stock setting WOT about 4.5v



Best I could get the ITB TPS was .6 @ closed



and 4.4 @ WOT



The throttle linkage was alot easier than I thought! I used an extra throttle bracket from a D16a6 intake manifold, and it fit right off the backside perfect!



This kinda pissed me off, I mounted the TPS upside down, it was hitting the master cylinder. So I had to rotate it, and re-adjust it.



So now your thinking, what engine is he going to put this on? something cool? something built? haha, I dont think so, This was a b16a I required from doing a motor swap awhile back, the ****** was completely seized and full of rust in every cylinder, I pretty much thought it was junk, I gave the bitch a quick hone and threw a set of NAPA rings in, and even reused the head gasket, lol (more info, refer to the Trailerpark B16a thread on HMT)

http://www.homemadeturbo.com/f...14730



And of course I'm using the 85 Dollar Ebay 3 1/2-1 High Flow header, hahahaha



Overall, for a couple hundred bucks it was well worth it, it took a little bit to get running, the idle was pretty easy, a nice 1100-1200rpms. It sounds pretty interesting too, especially when vtec kicks in. I'll try to post some sound/video clips soon. The RPM range seems to be way up there, doesnt really pull good til about 7000~9000. (oh ya, high performance 1g Automatic b16a valve train)

How is this running? I use a Zdyne Gold SECU, I can change the maps however I like. Its a modified PR3 map with about 5% more fuel. I still need to go to the dyno and see what this thing is putting down.. The *** dyno says about 160-170ish





Enjoy

 

dude thats EXACTLY what im planning to do.....you saved me alot of trouble do you happen to have any pics of the b16 manifold cut? do the TB's line up with the ports on the flange good? i was thinking about cutting off the runners entirely, and welding 3in long straight runners. its going on a 1g b16 with auto cams as well

 

yes, please... get more technical with how you did this! and thanks!

 

jesus, how much more technical do you want me to get? I took lots of pics, and pretty much explained everything. I didnt take a pic of just the runners welded on, I had already slipped on the couplers, sorry.. they are just straight tubes welded straight off the stock mani.

Feel free to ask any specific questions and I'll try to help out, I just slapped this thing together.

Jeff

 

Wow very impressed if you make anymore of these you could probably sell them for a grip

 

Look nice I want a vid to hear how it sounds.

 

Wow, very impressive.... question, is it necessarry to add the runners to the manifold base? Is that to make the transition smoother, trying to match the port shapes? anyway, Congrats to you!

 

I give you a big , very nice indeed. I had once bought tires from this guy I knew online, and he had a Neon..(i know a neon... blah) but he had pretty much done the same thing you have done here, he grabed the Suzuki TB's, and made his own, ITB's.... they were very nice, if I have some welding knowledge, and welder for that matter, I would like to customize something myself.

Very very nice, like someone said earlier, you should mass produce these, if you have the time, and make some dough!

 

The runners look a little long, but everyones a critic

In all seriousness though, that looks amazing, very well done. Also to add to your silicone couplers argument, there are quite alot of cars that came with stock ITBs or intake manifolds with cut off runners that use silicone couplers, one of the top of my head is alpha romeo used them on one of their production cars, cant remember which one though.

-sander

 

Nice work Jeff, taking any mystery and confusion out of this.
speaking of mysteries, how did the vacuum work out? care to share the generic maps for this?
good work indeed.
Stan

 

Looks good

I plan to start my project very soon.

 

Ill have you know what youve done, you have seriously just inspiried me.

just bid on a set on ebay



-sander

 

funny... i just fabricated throttle plates for a set of honda 954RR ITB's for my project car. Nice thing with the honda units, same TPS sensor. 42mm at the plate.. i've overbored them to 1.750" Pics sometime next week after i get them back together.

 

damn, nice work man, looks really nice, your gonna have to post up a vid/soundclip. i wanna hear those babies good luck with it

 

was zedyne the only way to get it started? Or can you run stock ecu pr3 program with the itb's??

 

The trailer park B16 owns!!!

 

 

people like you make me happy

 

soo very nice...so an Aluminum tubing was added @ the intake manifold and the hose covered over it?

 

what suzuki were the throttle bodies taken from???
also do you have any other pics of the map sensor setup

 

GSXR 1000, I think the 750's are the same too, I tried getting my hands on a set of Hybusa throttle bodies, but they are a bit rare (slightly bigger) I dont have any other pics, Its really simple though, 4 little ports of each runner going into one line that goes directly to the map sensor.

Hose isnt to cover it, its so you can connect the 2 pieces together. Just like you would connect 2 charge pipes together with silicone adapters.

Not sure, I dont see why it wouldnt start with a stock pr3 (tuning maybe difficult), I just have had this Zdyne secu for almost 2 years now.



Thanks, the vacuum worked out alot better than I expected, I still think I'm going to make a little collector box for the vacuum to go into, might give the map a better reading. Generic maps? I assume your talking about my fuel/spark maps? stock PR3 tune with 5% fuel added and the timing was modified all over the map. Like I said I still need to hit the dyno to see full potential of these things.

They look long, but I compared them to some other B16a ITB setup at a local import shop and they were just about the same length, good for top end I guess?

Thanks, I wouldnt even know what these things would be worth? couple hundred bucks I guess?

Yes, because the runners are not perfectly round, and I'm not sure exactly how they would align up, nor mount? I wouldnt suggest welding them directly to the manifold either, the aluminum is very thing, and after you heat up the ITB unit, I am almost 100% positive the butterfly and bore will be distorted. Hell just the welding on the small runners warped the inlet flange, had to get that surfaced too.

Glad you guys enjoy this, it was kinda a fun project. When I get it dyno'd I'll take some videos and stuff, Its so freaking rainy out here right now, its going to be weeks before we even get a clear day

Btw, I'm also running DSM 450cc injectors

Jeff

 

nice work...

 

yeah I want to do that now....

 

for how sweet it is i hope it runs damn good for the work you put in.

 

would gsx 1000 TB's work?