ITB B212

[squaab99t]

Figured I "needed" a new project and have this N/A lump with 1400 miles that needs a second life.
Yamaha ZR1 2021 throttle bodies with DBW. Grafted to a Genuine Saab T5 CNC machined intake flange. Used Icengineering modeling blocks to mockup the routing and lengths. This is the same kit I used for my turbo manifold. Not the correct diameter, but the CLR are still valid.

Plan is to use a standalone ECU for the drive by wire throttle and 2 stages on the injectors. Low RPM, use the stock location by the head and as the revs rise, transition to the injectors on the T/Bs.

[squaab99t]

More images

[99Super]

Looking good!
I have a set of GSX-R TBs and a 9000 short manifold. I'll be watching to see how you handle some of the issues!

[squaab99t]

I think the main issue was the transition from the Saab runner spacing to the narrower T/B centerlines on the Yamaha. The Suzuki maybe a similar width.

[squaab99t]

Get on the horn....
Velocity stacks, good fun making these. Turned a nylon mandrel to act as the die to create the horn. Working on attachment scheme, so I can swap out lengths to help find the power band sweet spot. Some say you can use two different length pairs to widen the power band? All part of the learning.
Mods to the fuel rail attachment. Flipped the tabs around and set at a different angle to pick up an imaginary stanchions off 1 and 4 runners. First time using a back flood argon fixture. I made it so it works with a Noga mag based articulating arm. Able to find its happy spot super quick. No need stacking blocks, clamps, or fuss.

[squaab99t]

Fuel rail post/stanchion attachments. 3/4" 6061 bar stock, M6 drill and tapped and added some flair and weight reduction. Counterbore the bases so the welded area material thickness would be closer.

[99Super]

How did you decide which ITBs to use? Size? Features? Cost?

[squaab99t]

How did you decide which ITBs to use? Size? Features? Cost?

Size wise, I figured some simple math and assumptions: 1000cc engine at 14k RPM, more efficient flowing head would be enough for a +35 year old head design, 2.1 liter at 7k RPM.
Features: Robust TPS since it will be running Alpha N. DBW so I can learn PID and no cable/linkage routing to deal with.
Cost: this was a sweetheart deal. Brand new, fuel rail, Bosch injectors, MAP sensor, and TPS. Under 200 usd shipped. I think this is around what you would pay for at a bent-bike salvage?

[Geoff]

This is super pretty!
Are you going to run 2 fuel injectors per cylinder?
What car will this go into?

[squaab99t]

This is super pretty!
Are you going to run 2 fuel injectors per cylinder?
What car will this go into?

Thanks, I think Frankenstein would appreciate that. Functional art.
The thought is a 2 stage injection. Use the stock injector location for low rpm and then transition to the injectors up stream at higher engine speeds. I'll have 2 injector fuel maps to do the hand off.
I have a '77 99 EMS trunk that will be the likely candidate. Right now it is slated for a spare 2.1 for a motor build.
Some more progress pixs. Bored out the posts to a larger ID. Made for easier welding .125" to .063" is a better match.

[Krizzie]

Welding porn asusual!

Is it a stock B212 bottom end?

Curious to see how much more power these will generate

[squaab99t]

Welding porn as usual!

Is it a stock B212 bottom end?

Curious to see how much more power these will generate

Have not broken down the engine yet, so we will see what is needed, Only had 1400 miles, but was not properly moth balled.

[squaab99t]

Getting the velocity stack attachment sorted.
Send Cut Send is a great service. 4130 sheet and cork-rubber gasket. Be sure your CAD file is correct physically and no hanging Chads.
Mock up with 3 super glue tacks. Little challenging with the two upper fastener locations.
I'll add a slot and pinch bolt to create a collet type arrangement to retain the aluminum tube.

[99Super]

Those look great! A friend recommended send cut send so I'm working on sending him a file to make the oil cooler bracket out of aluminum and then bend for both right and left coolers.

[squaab99t]

Those look great! A friend recommended send cut send so I'm working on sending him a file to make the oil cooler bracket out of aluminum and then bend for both right and left coolers.

I've used Send Cut Send on a few time. Much better than having a water jet or plasma CNC in my shop IMO. Even the cost of procuring small amounts of sheet stock is off loaded to someone else.
They also have bending services, so it it is totally plug and play. As long as you have the bend directions/angle correct. The other issue in bending is the temper/heat treat. T6 aluminum will most likely crack when bent. Need it in T0 condition to get a nice bend. You can DIY with a torch to anneal and do your own forming.