viva_brasil
Well-known member
All exhaust parts are in - can't wait to start working on it
Build Thread: 999S "4VSBK"
- Thread starter viva_brasil
- Start date
viva_brasil
Well-known member
*Edit - also went by Motion Pro for the throttle cable elbows. Last time I went, the guy that I worked with was super helpful and we pieced together a custom cable for the 2VSBK (single cable into a split that actuates two throttle bodies). Totally different experience this time, this dude (different from person from the previous experience) didn't want to help at all - they'll only do full custom cables or nothing basically. Anyway, I was able to bend the hose / housing myself -which worked really well. I was planning on making my own elbow out of very small steel or aluminum tubing, but wasn't needed in the end.
Had some time today to start fabricating the exhaust stuff. Will try to take these initial parts to get fully welded before continuing to build. I don't have SS wire nor the right gas for SS welding, but can get by for some quick tacks.
Beginning of the vertical cylinder manifold - had to modify this to clear the 848/1098 shock:
And modified the horizontal cylinder manifold - removed the cat and re-routing it for an under-belly muffler:
Mocking up the horizontal cylinder muffler:
And what the mufflers will look like roughly:
My current idea is to have dual side exits with mufflers angled rear-wards slightly. Initially was going to do a tail-mounted muffler for the vertical cylinder, but not much space and may get too hot.
Had some time today to start fabricating the exhaust stuff. Will try to take these initial parts to get fully welded before continuing to build. I don't have SS wire nor the right gas for SS welding, but can get by for some quick tacks.
Beginning of the vertical cylinder manifold - had to modify this to clear the 848/1098 shock:
And modified the horizontal cylinder manifold - removed the cat and re-routing it for an under-belly muffler:
Mocking up the horizontal cylinder muffler:
And what the mufflers will look like roughly:
My current idea is to have dual side exits with mufflers angled rear-wards slightly. Initially was going to do a tail-mounted muffler for the vertical cylinder, but not much space and may get too hot.
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viva_brasil
Well-known member
Yea I wear a respirator at home with ventilation, and we have a fume extraction system at work. Some years ago I was welding a galvanized rod to a plate and inhaled just a bit by accident, wasn't fun.
I have a local welder doing the full welds on the exhaust since it's a bit trickier... Combining different thickness material, possibly different types of stainless, though pretty sure the OEM stuff is 304. Doing it piece by piece in case the metal contacts a bit here and there, should have the initial batch of welded tubing back by tomorrow.
I have a local welder doing the full welds on the exhaust since it's a bit trickier... Combining different thickness material, possibly different types of stainless, though pretty sure the OEM stuff is 304. Doing it piece by piece in case the metal contacts a bit here and there, should have the initial batch of welded tubing back by tomorrow.
viva_brasil
Well-known member
Couple updates - got the initial exhaust parts back, decided to take the bike off the jig for the final stuff. Did lots of thinking about the headlights, finally have an idea that I'm happy with and think will complement the style I'm going for.
Also sanded, buffed, polished, and waxed the tank (after having clear coated the bare metal tank last week). Had issues getting the pump back in because of the shitty OEM seal on that thing. Found an equivalent off-the-shelf seal at Grainger that worked much better and managed to get the pump back in today.
Tank:
Vertical cylinder manifold:
Horizontal cylinder pipe:
Some pics off the jig:
Need a better frame plugging option for the back...
Also sanded, buffed, polished, and waxed the tank (after having clear coated the bare metal tank last week). Had issues getting the pump back in because of the shitty OEM seal on that thing. Found an equivalent off-the-shelf seal at Grainger that worked much better and managed to get the pump back in today.
Tank:
Vertical cylinder manifold:
Horizontal cylinder pipe:
Some pics off the jig:
Need a better frame plugging option for the back...
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viva_brasil
Well-known member
Taking some days off so won't be back to work on her till next week, here's what's left - parts/to-do's:
Parts:
- Clip Ons
- Tank grips
- New front brake lines
- Front lights
- Aluminum and SS stock
To Dos:
- Exhaust
- Rear tail light bracket
- Rear subframe plugs
- Front mount
*Edit / Add:
- Machine the suspension link and press in the new bearing, swap with current link
- Finish fuel lines
Parts:
- Clip Ons
- Tank grips
- New front brake lines
- Front lights
- Aluminum and SS stock
To Dos:
- Exhaust
- Rear tail light bracket
- Rear subframe plugs
- Front mount
*Edit / Add:
- Machine the suspension link and press in the new bearing, swap with current link
- Finish fuel lines
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viva_brasil
Well-known member
Quick updates:
- Front End: going with dual PIAA lights, making a mount for the gauges and lights out of carbon fiber. Getting the mold cut out of sheet metal.
- Clip ons, tank grips, and brake lines installed
- Getting the subframe end plugged by welding on some shim stock and will probably powdercoat it afterwards
- Got the suspension link modified and installed - 5mm machined from one end - with new bearing - and 5mm spacer added to other end:
- Front End: going with dual PIAA lights, making a mount for the gauges and lights out of carbon fiber. Getting the mold cut out of sheet metal.
- Clip ons, tank grips, and brake lines installed
- Getting the subframe end plugged by welding on some shim stock and will probably powdercoat it afterwards
- Got the suspension link modified and installed - 5mm machined from one end - with new bearing - and 5mm spacer added to other end:
viva_brasil
Well-known member
Couple updates of the exhaust, doing it piece by piece to get it right...
viva_brasil
Well-known member
Thanks :thumbup
Not sure exactly what you're referring to, but working from the head backwards:
cylinder head -> intake manifold / runner -> throttle body -> velocity stack with molded injector holder -> injector
The throttle bodies have a metal brace that connect them. The velocity stacks are usually sealed inside the OEM airbox.
viva_brasil
Well-known member
Some updates:
Front headlight / gauge holder coming together with the PIAA lights:
Originally I was planning to use the aluminum piece as a mold and make some carbon fiber parts out of it... But on the other hand I'm considering just powdercoating it and using as-is, it's very sturdy. Getting impatient...
Got these extra lights, planning to mount on the sides with the brackets / using the frame tabs for fairings:
Also not as happy with how bulky these are in person... May replace them with something stealthier.
Transferred the 2VSBK bike over to the jig table, got the swingarm mounted. Getting caught up with that one while I wait on final things for the other one...
And I finally got around to making a reinforcement brace / parts tray for the jig, need to weld on the mounting tabs and get some steel sheet cut to put inside it:
Front headlight / gauge holder coming together with the PIAA lights:
Originally I was planning to use the aluminum piece as a mold and make some carbon fiber parts out of it... But on the other hand I'm considering just powdercoating it and using as-is, it's very sturdy. Getting impatient...
Got these extra lights, planning to mount on the sides with the brackets / using the frame tabs for fairings:
Also not as happy with how bulky these are in person... May replace them with something stealthier.
Transferred the 2VSBK bike over to the jig table, got the swingarm mounted. Getting caught up with that one while I wait on final things for the other one...
And I finally got around to making a reinforcement brace / parts tray for the jig, need to weld on the mounting tabs and get some steel sheet cut to put inside it:
jumph4x
Do more, bitch less.
Injector holder?! Holy hell, isn't that a bit early to be misting fuel? That's hardly injection at that point.
I don't imagine atomizing fuel that far up can possibly be effective. I'd be curious to see what that motor's specific output is.
EDIT: I am disappointed you're not using the steamtrain headlight assembly.
I don't imagine atomizing fuel that far up can possibly be effective. I'd be curious to see what that motor's specific output is.
EDIT: I am disappointed you're not using the steamtrain headlight assembly.
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viva_brasil
Well-known member
All the superbikes use the same "suspended injector above velocity stack" design: 749/999, 848/1098/1198, and the panigales... Outputs range from 120ish for the 749 and up to 200.
Edit: forgot to comment on the headlight. That blob is the most plastic-looking metal lump of shit I've ever seen. I was considering doing a metal tubular frame for the projectors, but the cast aluminum on those is junk too... So fastening them down would require a lot of work and didn't feel right with the rest of the bike. Biggest issue with the stock headlight housing is how far forward it protrudes because of the fairing design.
Edit: forgot to comment on the headlight. That blob is the most plastic-looking metal lump of shit I've ever seen. I was considering doing a metal tubular frame for the projectors, but the cast aluminum on those is junk too... So fastening them down would require a lot of work and didn't feel right with the rest of the bike. Biggest issue with the stock headlight housing is how far forward it protrudes because of the fairing design.
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viva_brasil
Well-known member
Slightly unrelated, but relevant... happened to be reading about this car today and noticed the super special motor has the same "injector suspended above velocity stack" design... which I learned is referred to as a "gantry fuel injection", and here's some commentary:
The new motor has a gantry fuel injection system, which has the injector nozzle as far upstream of the intake port as possible. This gives the fuel time to atomize while being tumbled in the natural turbulence of the intake tract. With a whopping redline of 10,200 rpm, the engine inhales a huge volume of air and injects the fuel upstream, giving the fuel a much better chance to create an even air/fuel mixture. In theory, an upstream injector cools down the intake charge to make a denser mixture with oxygen resulting in more power—in Billy's case, about 10 additional ponies.
The new motor has a gantry fuel injection system, which has the injector nozzle as far upstream of the intake port as possible. This gives the fuel time to atomize while being tumbled in the natural turbulence of the intake tract. With a whopping redline of 10,200 rpm, the engine inhales a huge volume of air and injects the fuel upstream, giving the fuel a much better chance to create an even air/fuel mixture. In theory, an upstream injector cools down the intake charge to make a denser mixture with oxygen resulting in more power—in Billy's case, about 10 additional ponies.
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viva_brasil
Well-known member
Some updates - almost done....
Working on the gauge and headlight mount:
Eye safety is of top concern:
Everything mounted up - PIAA lights with some extra LEDs, designed this to be super visible on sunny days for splitting. The PIAA lights are on their own circuit - powered up when ignition is turned on, will likely leave them on so they turn on whenever the bike is on. The LEDs are wired to the high beam, but the PIAA lights stay on when high beams are on, so I can flash them and keep them on.
Another angle:
I'll likely powdercoat the mounts black and add a X-brace type reinforcement for the front mount.
Final exhaust mock-up for the mounting tabs:
I fired it up and it sounds incredible. The pod filters are interesting, can hear what the injectors are doing - sounds like they give a little spritz of fuel after the fuel pump primes - kind of like spraying starter fluid in your intake... Mufflers actually pretty effective, thought it would sound basically the same as open headers, but it's very much tolerable with the mufflers on.
Working on the gauge and headlight mount:
Eye safety is of top concern:
Everything mounted up - PIAA lights with some extra LEDs, designed this to be super visible on sunny days for splitting. The PIAA lights are on their own circuit - powered up when ignition is turned on, will likely leave them on so they turn on whenever the bike is on. The LEDs are wired to the high beam, but the PIAA lights stay on when high beams are on, so I can flash them and keep them on.
Another angle:
I'll likely powdercoat the mounts black and add a X-brace type reinforcement for the front mount.
Final exhaust mock-up for the mounting tabs:
I fired it up and it sounds incredible. The pod filters are interesting, can hear what the injectors are doing - sounds like they give a little spritz of fuel after the fuel pump primes - kind of like spraying starter fluid in your intake... Mufflers actually pretty effective, thought it would sound basically the same as open headers, but it's very much tolerable with the mufflers on.
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viva_brasil
Well-known member
Couple more before wrapping up today:
And the chain side:
And the chain side:
viva_brasil
Well-known member
They're removable and seem quite secure when on.
Johndicezx9
Rolls with it...
Bravo, sir... BRAVO!
You made the 999 "desirable"! :thumbup
You made the 999 "desirable"! :thumbup