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GS500 build thread... cf tanks, internal supercharger, etc

just a thought... but instead of an air to air, couldnt you use a liquid intercooler?

while it would add a few pounds it does give you alot more flexibility with your design...

you could have the cooling system run low pressure and then its VERY easy to deal with flexing hoses.... versus a "high" pressure air line.

just a thought though.
 
Whisky_Richard said:
How exactly are you planning on sealing the ends of your CF pipe?
Click to expand...

I'll machine some aluminum flanges for the ends that need to mount up to something flat and bond the pipes to them. For places where it's just a pipe butting up to a pipe(i.e. the side of the intercooler that already has a pipe stand off), silicone hose connectors should work just fine.
 
Starshooter10 said:
just a thought... but instead of an air to air, couldnt you use a liquid intercooler?

while it would add a few pounds it does give you alot more flexibility with your design...

you could have the cooling system run low pressure and then its VERY easy to deal with flexing hoses.... versus a "high" pressure air line.

just a thought though.
Click to expand...

Space is already at a major premium. A liquid/air intercooler requires running a heat exchanger somewhere, a reservoir, the needed pump, etc plus the intercooler itself. Adds a lot of weight and takes up a lot more space
 
just for "why the hell not" factor, you should add the capability to run it just as an air compressor. it might come in handy for a track day
 
auntiebling said:
just for "why the hell not" factor, you should add the capability to run it just as an air compressor. it might come in handy for a track day
Click to expand...

There's a technique like that described in an old Honda manual, if I remember correctly, as part of roadside flat repair procedure. One of the last steps is disconnecting spark plug wires, taking out one of the spark plugs and using that cylinder to inflate the tire.
 
auntiebling said:
just for "why the hell not" factor, you should add the capability to run it just as an air compressor. it might come in handy for a track day
Click to expand...

Can't imagine it'd be that hard to do. I'd just have to figure out some way to keep the exhaust valve on the compressor to keep from opening. Not sure it's really worth the effort though.





On the project note, I'm in the machine shop today. Getting the throttle bodies sorted out. Pictures will be posted a little later tonight.

Also ordered 10 A123 batteries for making my own battery pack. Need the space and not the weight from the stock battery.
 
mllcb42 said:
Not sure it's really worth the effort though.
Click to expand...

seems a little ironic, coming from a guy undertaking a project such as this


Also ordered 10 A123 batteries for making my own battery pack. Need the space and not the weight from the stock battery.
Click to expand...

from where and how much per cell? i'm kicking around this project myself

Alexey said:
There's a technique like that described in an old Honda manual, if I remember correctly, as part of roadside flat repair procedure. One of the last steps is disconnecting spark plug wires, taking out one of the spark plugs and using that cylinder to inflate the tire.
Click to expand...

awesome. a fuel air bomb/tire
 
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auntiebling said:
seems a little ironic, coming from a guy undertaking a project such as this
Click to expand...
Perhaps, but it's a lot of extra effort that doesn't really go towards anything, other than because I can


from where and how much per cell? i'm kicking around this project myself
Click to expand...
Bought a 10 pack off ebay for $60 shipped. I've heard of slightly cheaper prices, but they're uncommon. Was also from a US seller instead of overseas.
 
So time for a bit more technical of an update. Lots of pictures, but not super exciting.

Spent the afternoon in the machine shop, getting the throttle body taken care of.

After removing the extra butterflies and linkages, I was left with a couple holes in the throttle body like so.
tb1.jpg

Obviously as this is a pressurized system, I can just have a hole.

The idle valve mounts to the other throttle body, so I had to make mounts for it. There were supports in the throttle body casting left over, but they weren't drilled out.
tb2.jpg


So I made a set of plugs for the holes to be press fit in. I also made a pair of spacers to properly position the idle valve in the same spot it sits on the other throttle body.
tbspacers.jpg

tb5.jpg


The actuator on the idle valve presses on a lever coming off the butterfly valve from the other throttle body. I had to take a section of a rod, thread it so that it would screw on to the butterfly valve rod, then press the actuator for the idle valve to it.
tb3.jpg



And we're ready to go.
tb4.jpg
 
any reason you have it set to show leftover material in between pieces, but not in the heel guard? also, I personally would want a considerably thinner piece for the heel guard than the rest of it.
 
.. and to think I would have just popped some freeze plugs with some epoxy in the open holes. :p

Looks good.
 
Junkie said:
any reason you have it set to show leftover material in between pieces, but not in the heel guard? also, I personally would want a considerably thinner piece for the heel guard than the rest of it.
Click to expand...

The heel guard is supposed to be thinner. Glad you pointed that out. I've fixed it.

The material in the middle of the heel guard is completely removed, because I need to put some retaining bolts through there for when I do the final cuts to remove the material. Same reason there are random holes in the excess material.
 
mllcb42 said:
The actuator on the idle valve presses on a lever coming off the butterfly valve from the other throttle body. I had to take a section of a rod, thread it so that it would screw on to the butterfly valve rod, then press the actuator for the idle valve to it.
Click to expand...
Or you could junk all that stuff. I have simulator that makes ECU think servo and stps are there and working :)
 
After hours of test fitting, etc... This is really the only place the intercooler will fit.

intercoolernaked.jpg

Pros: Fits nicely, isn't obtrusive, distance between the throttle body and the air tank is minimal

Cons: Airflow is meh.

I'll have to get creative with some ducting.

The pipes will tuck into the frame right behind my legs.
intercoolerlegclearance.jpg


Found some room for the electronics.
electronics-mock-up.jpg


I need to actually cut a recess into the seat for the ecu to sit in though.

My Lithium Ion batteries to replace the stock battery showed up as well. Fit perfectly right up against the intercooler. I'll start with four and go to eight if needed. They stack up so nicely.
battery-front.jpg

battery-side.jpg



Hmm, first time I've noticed the almost carbon fiberesque fabric the seat is made from.
 
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