c20ne R1 bike carbs mod with custom manifold

c20letnova · 11-08-2008, 11:17

Hello everybody!

We are building a c20ne 2.0l 8v engine with R1 bike carbs.

The c20ne's are cheap and easy to get. The manifold can also be attached to the c20xe. For right now we are building one for a 8 valve engine. Hsp ratio aprox. 180.

The manifold will be custom made and will have other options then the regular bike carb manifolds. It will be cnc machined from billet.

By the way my name is Alex. My good friend Gunther is doing all the machining. We are in Germany. (Hope my english is ok).

I try to cover the complete process with several pics.

Inlet runners:

Top off inlet runner. Snaps right into the rubber manifold and has a perfect fit.

The R1 carbs are 40mm on the inlet. Our inlet runners are 40mm on the top and 37mm on the bottom. This will help to create a better venturi effect. Check out the pics.

Top:

Bottom:

Inlet runner with the carb attached:

More pics later...

DaveB · 11-08-2008, 11:25

Project looks good. Your english is good too

Warm welcome to Migweb

Mitch2.0 · 11-08-2008, 13:41

Nice work, and nice English!

Davey · 11-08-2008, 14:10

Tidy work!

I wish I had a lathe

c20letnova · 12-08-2008, 20:58

Cutting off the base for the manifold.

Base is made out 30mm billet. Using the gasket to mark of the dimensions.

tom reid · 13-08-2008, 18:23

Look forward to seeing more of the excellent work.

The Simps · 13-08-2008, 19:57

this should be good!

rwdmad · 13-08-2008, 20:00

workman ship looks good, keep the updates coming

Gaz86 · 14-08-2008, 02:38

workmanship looks great, i take it ally isnt worth that much where your from

c20letnova · 18-08-2008, 20:45

Used super glue to put the cut off (original manifold) onto the base plate:

We need to do that to pre drill out the mounting holes.

Pre drilling the mounting holes:

Pre drilled and lined up to check for fittment:

Drilled an fitted with stainless mounting bolts:

rc · 18-08-2008, 21:05

nice bit of engineering there lads

c20letnova · 18-08-2008, 22:59

Here we go! Starting to cnc machine the inlet ports and the manifold.

Mounting the head onto the cnc machine:

First step in drilling the inlet ports:

Measuring shape and size of the inlet ports.

Machining the inlet. (preshaping the head without the manifold)

Inlet Port (cnc machined and with an optimized angle for the gas flow / inlet valve).
The port is not finished (The steps will be smoothed out by hand with porting tools).

c20letnova · 18-08-2008, 23:32

Shaping the inlet ports:

Base plate is mounted onto the cylinder head.

First step is to countersink the mounting holes for the inlet runners.

Inlet runner(will be welded to the base plate)

Starting up

Countersinking (inlet runners)

Final shaping of the port (manifold and head).
This is done to achieve a perfect blending of head port and inlet manifold port.

c20letnova · 19-08-2008, 10:49

Base plate and head together

GeorgeGt · 19-08-2008, 10:54

Nice work! So port size will be 37mm measured from the head ? looks a lot more from those pics. I used 39mm port size with custom intake on one c20ne engine and oh boy does it like to rev

c20letnova · 19-08-2008, 10:55

This is how the port looks with the manifold attached to the head

Test fitting the inlet runners.

Let me know what ya think so far!!

B8 GHY · 19-08-2008, 12:25

that is something...

I notice your opening up the ports, this might hinder low end gas flow, nonetheless top job.

keep us posted dude

GeorgeGt · 19-08-2008, 12:32

We didnt notice much loss of low end power on my m8`s c20ne engine , and we ported it to 39mm measured on head, runners on manifold are 45mm and tappered to 39mm on the head.

That looks the tits , and now i understand why it looked so big on the pic. keep up the good work

B8 GHY · 19-08-2008, 12:55

Quote:

Originally Posted by GeorgeGt

We didnt notice much loss of low end power on my m8`s c20ne engine , and we ported it to 39mm measured on head, runners on manifold are 45mm and tappered to 39mm on the head.

That looks the tits , and now i understand why it looked so big on the pic. keep up the good work

was it benchmarked with standard size ports?

well port size varies on powerband, cams, and fueling setup so if you guys want a screamer then I guess 39mm is pretty small, dont know if you guys know but im sure c14se n c16se heads have 37mm ports.

I wish I had the time and equipments to do the above, I have so many plans but no time or money

c20letnova · 19-08-2008, 22:39

The ports are not finished yet. They will receive a extreme port job.
Oversize inlet and exhaust valves (polished).
3 Angle valve job. (with blending the valves to the seat).
Bronze valve guides etc...
Reshaping the comb. chamber (for better cylinder filling).

Even the stock ports are large. But we will have huge ones!
We are also reshaping the inlet port (welding ally onto the port and onto the plenum and blending it with the porting tools.

We will also run a high lift cam (296 degrees).
c20xe parts (pistons, con rods, crank)

Here is a inlet port
Stage 1:

Stage 2:

Ports are not finished at all.
Ported more than 5 hours today just blending it with the manifold and started to give the inlet port a rough shape.

c20letnova · 19-08-2008, 23:06

Manifold:

More pics will follow...

c20letnova · 22-08-2008, 22:48

more pics:

Looking through manifold into inlet runner (bottom to top):

Gaz86 · 22-08-2008, 23:01

your very handy with a cnc machine and billit alloy, one question....whats the value of alu in your country?

c20letnova · 22-08-2008, 23:37

The ally is from previous cnc work. We just looked in different corners at the shop an my friend Gunter found the goodies.

We will prep the inlet runners for water/methanol injection jets next week.
The base plate will also be cut down and machined. We hope to get it welded soon.
The porting and blending takes so much time!

Tools that i used for porting:

c20letnova · 28-08-2008, 21:16

Exhaust port stage 1: