Members Page/Dave Brul/Intake - VEMS wiki www.vems.hu

MembersPage/DaveBrul/Intake (2006-03-16 04:43:08)

Intake project

After aquiring some cheap individual bike throttle bodies of [ebay], i looked into ways of mounting them e.g. what would be required, where to mount them, plenum design, inlet length etc.

So far i have have aquired the following parts:

2001 Suzuki GSXR 1000 itbs (tapered from 49.9 at the inlet to 41.9 outlet)
4 x ~300cc @ 4bar (300 x 3/4 = 240cc @ 3bar) pink Bosch HighZ injectors (new type)
4 x tapered stacks / runners

The current setup already has the following:

4 x 391cc @ 3bar blue Bosch HighZ injectors (new type)
stock inlet manifold

The idea is to use an engine simulation program to determane the optimal runner length for my engine. The plenum size and shape wil be optimized using FluidModeling. Stock manifold will be cut to make room for the itbs and stacks.

I will be using a total of 8 injectors on the engine; 4 pointing directly at the valve opening, and 4 just after the throttle body butterflies ideal for a staged setup. The GenBoard/UnderDevelopment/StagedInjectors code needs to be finalized, current implementation will be modified in favor of the more general approach. The general approach does not only support different injector sizes more easily, but also different grades of fuel for the first and second injector set.

Another thing to look into is the FuelSystem, might need an fuel pump upgrade to deal with the 'massive' injector flow of the two injector sets combined. How can the pulses of the switching injectors on the fuel rail be dampened, maybe an accumulator/damper is needed ? After some chats on irc with MembersPage/JÃƒÂ¶rgenKarlsson and MembersPage/EmilLarsson, it was decided to drop the accumulator idea, with their help a [initial fuel system design] was constructed.

There is a problem with this setup. The 2 FPRs will have a slightly different threshold pressure. The pressure in both rails will be roughly the same: == the pressure of the FPR with the lower pressure. This means that the FPR with higher pressure will not open, and the end of that fuel-rail will get hot, maybe boil in the worst case.

Worst case: when one bank (secondary set) is shut off for a long time, that will really get hot if it's in the lower P FPR branch. Consider if it's possible to Y the branches and use just 1 regulator ... the only correct way to do it.

After some feedback from the community, [this is the new FuelSystem design], the fuel lines will be -6 AN (6/16th of an inch) all fittings will be AN fittings

News / Progress:

23/04/2005: Not much progress on the intake project, im currently sourcing some bigger injectors to supply the 'enhanced' engine with fuel

26/01/2005: Project kickoff!

Pictures:

picture of the itbs, stacks and injectors

[rough sketch of a potential airbox]

external pics (not mine) just here to show how nice it _can_ look :)

[850hp Bosch pumps and filters] [850 hp pumps installed] [swirl tank]

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