c20ne R1 bike carbs mod with custom manifold

[c20letnova]

Say hello to my little friend...










To overcome the biggest problem in running bike carb's is to avoid different pressures to each of the four carb's, causing them to run way out of synchronization, resulting in inconsistent, uneven, erratic power.


This little Item takes all fuel air circuits, from the MAIN AIR JET LOCATION, (via tubing adapters, and tubing), and routes them all into one location, so that each carb gets exactly the same amount of air all the time. The result is much smoother transition areas. The icing on the cake is being able to adjust the amount of air you are letting into the system, thus you can meter the air/fuel mixture, from one location, without doing anything to the carbs. And the system can even be installed without having to go into or removing the carbs at all, under normal circumstances.

[The Simps]

This is coming along very nicely!

I take it you're using a dizzy and vacuum advance to control the carbs rather than management?

[c20letnova]

Yes that is right. Just the dissy and that's it.

[c20letnova]

Here are some pics from welding up the inlet ports to raise the port for a better port filling.







Here is the port where you usually find the hole (god knows why its there)
Does anybody know why opel put a hole in there?
Machined a plug and welded it in.




Pics from welding of the base plate will be posted tomorrow...

[c20letnova]

Welding the inlet on the base plate:

All ports received a weld in the lower part to match and raise the angle on the inlet port.












Will work on it tomorrow...

[makemadam]

Nice to see such dedicated work going into a custom mod. Looks awsome keep it up!

[c20letnova]

Worked on the base plate today...


First smoothed out the welds of the base plate:








Checked for straightness and found out it need to be resurfaced:





Resurfacing:








Finished:





Resurfacing the inlet side of the head (welds):





That's how the inlet ports look with the welds for raising the port:




Starting to work with the burr:

Stage 1:


Stage2:



I will continue to work on it on monday...

[The Simps]

I don't understand the reason for the weld? Is there a low spot there and you're trying to smooth it out?

[c20letnova]

The plan was to redesign the inlet ports for better cylinder filling and for enhanced gas flow. To achieve this the angle of the port has to be changed within the "limits" of the head.

We shaved a 45° angle at the top off the port and the bottom remained normal. After open up the port there was a gap between the bottom of the port and the bottom of the inlet port of the manifold. Therefor the whole inlet port has to be raised by adding material to the bottom of the ports.

This was done by welding a lip on both inlet ports (head/manifold). It was not much but it has to be done to keep up the speed of the gas flow and to avoid any turbulences.

We don´t have a 5 axis cnc machine so we have to do a lot of porting by hand and use the machines that we have in the shop. I would have designed a whole new billet cylinder head but i think this is way to expensive for this low budget project. By the way the engine will be in a vauxhall nova.

We also use cold weld to refill some spots in the inlet ports (Can´t do that in the exhaust port).

Hope this explains it a little bit.


Here are some pics from today:

These are the ported welds on the inlet ports of the head.

[c20letnova]

More work an the inlet ports...


...worked on the upper part (rounded the edge at the 45° angle) and more work on the lower section of the port...


This is the upper part of the inlet port: (It is facing down now as you can see)







I tried to round up the angle from the 45° to the roof of the port to speed up the in comming air/fuel mixture.



Lower part of the inlet port:






Photo was taken with inlet plenum attached.
As you can see there is still a spot where i need to fill some material to fix the angle.

Just take a look in the back!
The darker area is added to blend in the base plate port with the inlet port. There is no visible edge or so where the manifold touches the inlet port (at the bottom). The top still needs to be worked on !.


Hope this is not boring for all of you who are watching this but the head work takes a whole lot of time and hopefully i will be finished with the port job this week.

After the port job i will work on opening up the valve seats. For that i have to machine all the valve guides. Found some very good ones on the exhaust side !!!!

That´s it for today

[The Simps]

Whole lot of time consuming work going on there - fair play to you lad

[c20letnova]

Fitted the inlet runners and started welding...



The welding will be finished by Saturday

[c20letnova]

Welding was completed today !!

Used thick welds to make sure that all vibrations are eliminated. Should be good enough.




















Underside still needs to be worked on. Extra welds to secure the inlet runners at the bottom of the baseplate.






Next step is to even out anything inside the runners that eliminates smooth gas flow (uneven part where the runner meets the manifold). This will ensure that there is no spot left from the carburators fuel distribution to the valve that will cause unwanted turbulences.

Off course this will be covered in pics...

[novashed]

looks the tits! you a welder by trade? almost a shame to put weld on that lovely machine work.

[The Simps]

Awesome stuff mate!

[c20letnova]

Here some pics form the inlet ports after blending the top to the manifold base plate.
(porting still not finished...)











Close up shot of the port:











Bottom of the port (close up shot):

[DaveyB]

wow!


you are gods!

[c20letnova]

Pic´s from the port on the inlet manifold. This will give you a better option to see that the shape of the port is totally changed form a round (stock port) to an oval port.


















There is still work left on these manifold ports. They still need to be smoothed out. I was not motivated and tired after work and i just worked on one port for about 30 minutes.

Will make a billet valve cover this week. I have a wonderful idea for the design. (Cool looks and very functional).


What do you think of the port job so far ...?

[corsakid]

amazing work

[c20letnova]

Here are the special valve guides for the exhaust valves.

They are made out of Beryllium. They came from a NASCAR Racing team.

Will use them only on the exhaust side because Beryllium is high heat resistant. These will last forever...

[TigraTurbo]

Its gonna scream like a bitch when its done........TOP JOB!!!

[c20letnova]

More work on the ports of the plenum:


























Ports where worked on with a carbide burr and then sanded down with a 40 grind mini flap disc.

The missing spots will be filled up next...

[c20letnova]

Filled up the missing spots to even out the ports:

[c20letnova]

Porting the cold welds:

[B8 GHY]

look good dude, keep us updated