Hey all, it's been about a week since my last update. I had originally planned on describing my overall design process in one (thorough) post and an accompanying video, but most of my time in the past week has been designing and prototyping custom throttle body adapters. I'm designing adapters that will perfectly fit both the 2013 ZX-6R throttle bodies and engine block, without needing any other processes. I'll use a nitrile rubber strip as a heat break between my nylon 6-6 parts.
Anyways, I've designed and iterated 5 versions of the adapters so far and am hoping that V6 will be the final iteration. From there I'll write up an in depth forum post explaining what problems I fixed with each iteration and showing the final design on the bike. I'll make a short youtube video to accompany it as well.
For now, enjoy these photos and captions of some prototypes so far.
V5 models on my mock intake in Solidworks. They're each a slightly different design here to account for TB spacing.
V3 mounted on bike to verify the retention ring design worked to hold the throttle bodies securely.
That's the perfect fitment I'm looking for.
Had to increase height a few millimeters to ensure Allen wrench clearance.
Offset hole design to perfectly fit on throttle bodies. In V6 I'm accounting more for injector flow and will be modifying some of the interior.
V4 solved all throttle body fitment issues, but forgot to account for the 2mm spacing difference between the ZX-6R throttle bodies and the KZ550 intake spacing.
(Not directly) Top view of V5 models. I added numbering to easily orient and identify the adapters.
Fronti view of the adapters. If you look closely you can see each of the larger ID's is offset 1mm in either direction to directly adapt the throttle bodies.