matt_gsxr
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| posted on 20/1/11 at 12:02 AM |
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airbox update
Just a quick update on some suggestions I got from here.
Nissan Pulsar GTiR plenum lid is an excellent bit of casting (thanks Flak), that is capable of boost and can be had for £25 from specialist breakers
(www.gti-r-us.co.uk).
Here is the plenum lid with the gsxr600 TBI's and a tufnol backplate and a couple of tufnol spacers. Note the gsxr600 trumpets (4x longer ones)
mounted in the backplate.
 
plenum sandwich
Here it just needs the lid putting on
 
plenum open sandwich
and here its all together.
 
plenum all togethre
I still have to get a few more bolts, bond the spacers to the backplate, and sort out a gasket (probably innertube rubber) to seal the lid.
Here is a photo of how it will sit in the engine bay. Looks like it was supposed to go in there. Very pleased with how this has turned out.
 
plenum in place
Just the intercooler, intercooler hoses, air filter, oil return, and tidying up the weld on the manifold to go...
Matt
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hobbsy
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| posted on 20/1/11 at 03:57 AM |
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Looking good 
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Pdlewis
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| posted on 20/1/11 at 09:18 AM |
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oh thats very nice
I might look into one of these the pipercross ones are so expensive
Build Photo Album
Updated 05/02/2009
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RazMan
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| posted on 20/1/11 at 10:35 AM |
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That really does look nice - good idea using Tufnol too. I was wondering what to use as machining out of billet alloy ended up very expensive.
Cheers,
Raz
When thinking outside the box doesn't work any more, it's time to build a new box
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CNHSS1
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| posted on 20/1/11 at 12:45 PM |
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could you machine an 'O' ring groove into the tufnol upper and lower surfaces to seal?
"Racing is life, everything else, before or after, is just waiting"---Steve McQueen
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matt_gsxr
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| posted on 20/1/11 at 03:07 PM |
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Raz. Tufnol, yes, pretty nice to work with (Bosch Router with standard wood bits) and was free as I had a big sheet lying around. The only problem
is the shed is now full of black dust.
According to the spec sheet, its good to 120deg C, (130deg C peaks), isn't too dense 1.4kg/litre), and although not that strong seems to be
fairly rigid in these 1/4inch sheets.
Flak machined from sheets of aluminum and did a sandwich (something you are familiar with), you could do the same with a bandsaw if you didn't
bother with all the tight curves around the bolts.
Interesting idea on the O-rings and not something that I had thought of. The only problem is that I would have to cut them freehand (too difficult
for me), or make a complicated template. I will probably bond the spacers and backplate together with araldite for strength, and use a gasket between
this module and the plenum lid, unless I can think of a way for me to do the O-ring trick.
I might need another spacer or two to leave more space above the trumpet. Not sure
Matt
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Andybarbet
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| posted on 25/1/11 at 10:28 PM |
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Im doing the same thing, using the pulsar lid as an airbox for my Gsxr throttle bodies, non turbo.
Any ideas how much space i need from the trumpets to the inside of the airbox lid ??
I have 2 sets of trumpets from the gsxr 600, therefore i have 4 short ones and 4 long ones. If i fit the short ones im thinking i could just make an
ali backplate and fix it straight onto the pulsar airbox lid, nice and compact, any opinions would be helpful.
This old thread seems to reckomend a minimum of 1/3 of the trumpet diameter space between end of trumpet and any object, i can do this easily using
the short ones.
Matt, nice job on your set up by the way
[Edited on 25/1/11 by Andybarbet]
[Edited on 25/1/11 by Andybarbet]
Give a man a fish & it will feed him for a day, give him a fishing rod & you've saved a fish.
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matt_gsxr
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| posted on 25/1/11 at 11:25 PM |
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Andy,
A good question, and one that has been worrying me too.
The problem with using the short gsxr600 trumpets is that unless you have long runners between the TBI's and the head you will have a very short
inlet tract. Very short runners will not be good for power (gsxr600 revs to 13.5k rpm).
I have used the long gsxr600 trumpets and have 2 x 0.25inch spacers.
The A.G.Bell book talks about 1.5x the inlet diameter as a minimum. So, for the 38mm diameter of the gsxr600's that would be 57mm
Who knows though?
Matt
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ruudbeckers
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| posted on 26/1/11 at 04:16 AM |
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Looks very nice, but is the inlet of the plenum not a little bit restrictive? It looks like the inlet is only a little bit bigger than the diameter
of the throttle bodies. So won't the plenum undo the benefits of the throttle bodies?
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cliftyhanger
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| posted on 26/1/11 at 04:34 AM |
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Was designed for a boosted engine, and in that application should work nicely.
As for NA, I suspect it is restrictive and really needs to be bigger. shame as it is a nice bit of kit.
Of course, happy to be corrected on the matter 
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RazMan
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| posted on 26/1/11 at 09:09 AM |
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quote:
Originally posted by cliftyhanger
Was designed for a boosted engine, and in that application should work nicely.
That's what I was thinking and a NA engine might struggle to get enough air in. It might be possible to open the bore a little or even TIG on a
larger piece of alloy tube.
Cheers,
Raz
When thinking outside the box doesn't work any more, it's time to build a new box
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matt_gsxr
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| posted on 26/1/11 at 10:04 AM |
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I'm not too worried about it being restrictive in my install. The basics of my install duplicate the Pulsar intake (4 ITB, turbo, same plenum
lid), and the Pulsar is good for 300bhp and these seem to be able to take bags of boost, my target is about 250bhp at less than 1 atm. Flak Monkey
has this set-up (with Supercharger) and gets ~300bhp, so it should be fine in a boosted application.
No idea on NA. Inlet takes 2.5inch silicon hose, casting is quite thick but there is over 2inch clear bore, and nice smooth transitions. So run the
numbers. I can measure exact dimensions when I get home.
The inlet could be trimmed back (remove the section with the BOV adapter) which would open things up. But if you are going to that trouble, then why
not make a whole airbox out of folded and rivetted/welded/bonded sheet.
Matt
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Andybarbet
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| posted on 26/1/11 at 09:14 PM |
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Im hopeing that it will allow enough air in on my install, i dont really want an air filter sticking through the side of the bonnet so was after
something for quite limited space & this fits the bill.
I am planning to make some spacer plates like matt has and when i get the engine in the chassis i will space out to get it as close to the bonnet as
possible, therefore giving me more clearance from trumpets to inside of airbox.
I have a friend thats a tig welder by trade so could get a piece of larger bore pipe welded on to increase the intake size but will try with it
standard first.
If you look at the pipercross 600 airbox dimensions, the pulsar one is basically the same size, just the inlet pipe is slightly smaller diameter than
the pipercross, it would be interesting to see what people think of the pipercross one ? it does look goooood, my budget unfortunately wouldnt stretch
to the pipercross one but im prepared to give this a go with a bit of time and effort because that doesnt cost me anything 
Give a man a fish & it will feed him for a day, give him a fishing rod & you've saved a fish.
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matt_gsxr
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| posted on 26/1/11 at 09:53 PM |
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standard Pulsar plenum lid i.d. is just under 56mm.
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matt_gsxr
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| posted on 26/1/11 at 09:53 PM |
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standard Pulsar plenum lid i.d. is just under 56mm.
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