Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
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Loupoz

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Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« on: May 15, 2019, 03:05:43 PM »
Hi all. Im designing an adapter for GSXR1000 ITBs to fit my M42. Im going to be 3d printing it (hopefully), some time in the future.

Lets kill some of the obvious 3d printing questions now. The prints ive been doing so far is only for prototyping, and they are in ABS-T. They arent meant to be functional, only meant as test pieces to verify the design IRL.

When i start making the final parts they will be made from fiber reinforced PA6 (Nylon) filament. This is very similar to what the manifolds on M5X engines are made from. Havent decided on which filament yet, but the candidates are these so far:
- Zytel® Glass Fiber Reinforced Nylon Polyamide Filament
- PolyMaker N600GF25
- XSTRAND™ GF30-PA6
- MARKFORGED ONYX

Enough text, lets have a but load of pics.

Design of the first test piece:






Sliced:


First prototype:










Where im at in the design process so far:








And this is currently printing


A little background: Im not an engineer, ive attended a technical high school, ive taken the shop part of a marine engineering education, im almost a certified mechanic, but above all else im a tinkerer and petrol head.

Any inputs and questions are welcome.

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colin86325

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #1 on: May 16, 2019, 12:08:34 PM »
This looks like a super fun project!   Looks great so far.  I'd make sure to have enough meat on the flange where the fasteners pass through, and be mindful of any weight that adapters need to support. Perhaps a gusset rib can be added to the underside of the adapter, if this is a concern.
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jerseytim

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #2 on: May 17, 2019, 06:16:07 PM »
looking good, amazing what can be made on the 3d printers when you know what you are doing
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Nick_318is

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #3 on: May 19, 2019, 04:49:02 PM »
Cool idea, I work for a plastics company and most of the manifolds are out of a 30% Glass Fiber, heat stabilized nylon 6.
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Loupoz

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #4 on: May 20, 2019, 06:29:02 AM »
Update









The holding bracket between the TBs dident turn out proper, guess i modeled the TBs wrong, ive been trying to correct it and need to print a new part to test.

On another account the adaptor part against the head might end up being aluminium instead. I may end up doing some stainless exhaust work on an E30, and the owner has access to 5 axis cnc machines, so we might do a little trade. Time will tell. It still needs a bit of development, as the main focus so far have been on making a nice transition between TB and head, it definitely needs some beefing up in other areas.

Next post to come will be with a couple of pictures of the printed trumpets:
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Loupoz

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #5 on: May 20, 2019, 10:45:33 AM »
Update

Random pic of my quick n'dirty enclosure lol


On the printer




Trumpets





On the engine. And yes it is "lying down", and ive rotated the pics, so some of the background might look weird.






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colin86325

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #6 on: May 30, 2019, 03:30:22 PM »
Nice progress. 
You know, with the availability of 3D printing, it would not entirely be too difficult to make a set of sliding trumpets ala the Mazda R26B.  Use a cheap Arduino or Raspberry Pi device to drive a pair of servos to control the trumpet length depending on rpm. 
Hmmm.
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cesco

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #7 on: June 06, 2019, 03:59:33 AM »
This is my first reply into that forum, but i know a lot about m42 and other bmw especially e30.
Really cool project, and really good drawing. It's not easy draw that geometry, i felt like buying 3d printer.
update us with the news  ;)
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lambertius

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #8 on: May 17, 2020, 04:46:18 AM »
When you get to the end, I'd recommend using a printing company like Shapeways. You'll get a much better result that a home printer.
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Loupoz

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #9 on: May 18, 2020, 01:46:08 AM »
Ive stopped working on this. Ive exported the entire project from Inventor, and put it in my drive. If someone would like to pick it up here the link https://drive.google.com/drive/folders/1f_GmlpH-2cRVT9sHTs5jKdeAVHld5uYN?usp=sharing

OBS: No i wont export to other file formats. If youre proficient at using a computer and google, youll figure it out on your own, and if you cant, then you shouldent be trying to play around with this anyways.
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lambertius

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #10 on: May 19, 2020, 04:27:09 AM »
Why did you terminate the project?
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Loupoz

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #11 on: January 05, 2022, 08:22:52 AM »
Quote from: lambertius on May 19, 2020, 04:27:09 AM
Why did you terminate the project?
I started working with BDS motorsport.
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lambertius

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Re: Designing and hopefully 3d printing GSXR1000 ITB Adaptor/Manifold
« Reply #12 on: January 22, 2022, 02:05:30 AM »
Quote from: Loupoz on January 05, 2022, 08:22:52 AM
Quote from: lambertius on May 19, 2020, 04:27:09 AM
Why did you terminate the project?
I started working with BDS motorsport.

Aw geez, good luck with dealing with Bruno. I've had nothing but trouble with that guy, and not just me! He is someone who knows how to get results because he has experience, but the downside is that you need to deal with him.   :-\





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