Wednesday 22 January 2014

TPS mount & plumbing

A little more work on the project over the weekend. I have fabricated a mounting plate on which to mount the TPS to the end of carb #1. This is simply a 3mm aluminium plate shaped to incorporate the TPS mounting holes and fixed to the carb through the top clamping rod and by way of a threaded hole into the side of the float bowl chamber. The clamping rod end needed an additional 3mm spacer in order to bring it level with the float bowl chamber.
The movement of the throttle will be transferred to the TPS through an M3 bolt whose head has been ground flat to fit in the TPS. The end of the throttle rod will been drilled and tapped to take the bolt. To fix the position of the bolt in place, both a locking nut and thread locker will be used.

TPS mount plate

TPS in approximate position.

The fuel pump mount has been cut out of the ZX6R tank ready for transfer onto the spare mc22 tank. It seemed a pity to cut up a perfectly good tank but all for the better!

ZX6R fuel pump flange

A mock mounting of the throttle bodies and fuel rail revealed that there was interference between the fuel rail and thermostat housing. Fortunately, I was able to overcome that pretty easily by adding an 18mm spacer underneath the thermostat housing mounting bracket. That pushed the thermostat housing down low enough to provide clearance for the fuel rail.

Fuel rail mock fitting (very approximate)

Ideas to deal with plumbing to the fuel rail have been run through also. The first option was to use standard threaded -6 motorsport hose fittings on one end of the fuel rail. That would involve a threaded adapter to sit into the fuel rail end. A 90 degree swivel fitting would then be threaded onto the adapter and lead onto the hose. The issue with this setup was side clearance on the fuel rail. The adapter and 90 degree fitting would need c.50mm end clearance to fit between the fuel rail and frame, which was not available.

The second idea was to run the same type of setup but with a 180 degree swivel fitting threaded into the bottom of the fuel rail and back on itself up towards the fuel pump. A quick CAD mockup of the carb bodies with blanking plates, injectors and fuel rail installed showed there wasn't the clearance available for this either.

CAD mockup of injector and fuel rail position relative to carb body

The final (hopefully) solution is to run a banjo bolt into the end of the fuel rail and clamp the fuel hose onto a barbed fitting. This would achieve something similar to the first  option but with less end clearance required. The other end of the fuel hose will be clamped to the original ZX10R fuel hose fitting to allow it to clip onto the fuel pump.

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