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Custom 75mm Throttle Body


TheBoz
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Galant VR-4 org Post #: 702032 posted 09/28/08 02:21 PM     Remind Me!  Send Private Message   Edit Post      
After my BBK Throttle body took a shit, my brother and I decided that we would build on that could handle the abuse that I was going to dish out. The Body is 6061 Aluminum, and the Butterfly and shaft are both 304 Stainless. The Rotor matches the stock rotor size, and the TPS Sensor is the stock one.

This is just Revision 1, we still have some changes we need to make to it. I need to find a better spring for it. Sometime the spring will bind and the throttle will slowly close. So after we have sourced a new spring this thing should be perfect.

We did some 25psi pulls on it last night and it held up great. We are going to continue beating on it to see if we can get it to break . however I dont think we are going to have any luck breaking it.

Let me know what you guys think.

IMG_0007

IMG_0008

IMG_0009

IMG_0010

IMG_0011

IMG_0012

IMG_0014

IMG_0015

IMG_0017

IMG_0018

IMG_0019

IMG_0020

IMG_0021

IMG_0022

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cOmpressor
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Galant VR-4 org Post #: 702033 posted 09/28/08 02:24 PM     Remind Me!  Send Private Message   Edit Post      
Looks awesome man! CNC machines are the shiz.



"Life's too short to drive slow cars"

1992 Galant VR-4 KG Just taking a break
2005 Lexus IS300 Dropped but mostly stock
2014 Evo X MR Plastering a smile on my face daily

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atc250r Galant VR4.org Moderator
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Galant VR-4 org Post #: 702034 posted 09/28/08 02:24 PM     Remind Me!  Send Private Message   Edit Post      
Looks really nice. What are you doing in lieu of a closed throttle switch?



"...if they're so into masochism, they should just really go all out and start modifying Mitsubishis. And using them as daily drivers." - Mike R.

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TheBoz
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Galant VR-4 org Post #: 702036 posted 09/28/08 02:25 PM     Remind Me!  Send Private Message   Edit Post      
AEM EMS, it just uses the TPS to see when it is closed.

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curtis Galant VR4.org Moderator
Space Blanket from NASA plumbed into the attic
475/1000


Galant VR-4 org Post #: 702040 posted 09/28/08 02:32 PM     Remind Me!  Send Private Message   Edit Post      
Sweet.



92 GVR4 0475/1000
Greenhouse Effect Green
Exceeds Mechanical Limits
"Put the dawg to work.
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Garfield Wright
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Galant VR-4 org Post #: 702041 posted 09/28/08 02:33 PM     Remind Me!  Send Private Message   Edit Post      
Nice work. It's about time someone did this.

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TheBoz
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Galant VR-4 org Post #: 702042 posted 09/28/08 02:39 PM     Remind Me!  Send Private Message   Edit Post      
After we get done with a lot more testing, I will offer them up to the dsm community. I need to go through and do a full run of pressure tests, and make sure it can handle the abuse of 35+psi runs. All in all it is working great so far, we need to adjust the throttle plate, it seems that we need to taper it a little, and we also want to add the ISC to this. We learned a lot about building Throttle bodies, it is not as easy as it looks, however there is really not much to them .

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cOmpressor
also-ran member


Galant VR-4 org Post #: 702045 posted 09/28/08 02:51 PM     Remind Me!  Send Private Message   Edit Post      
Quoting TheBoz:


IMG_0019




No half shaft mod LoLzx



"Life's too short to drive slow cars"

1992 Galant VR-4 KG Just taking a break
2005 Lexus IS300 Dropped but mostly stock
2014 Evo X MR Plastering a smile on my face daily

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strokin4dr
fighting them with a large needle
1280/2000
1135/2000


Galant VR-4 org Post #: 702046 posted 09/28/08 03:07 PM     Remind Me!  Send Private Message   Edit Post      
Nice work. You may want to bead the opening though, so there is less chance of the coupler blowing off.



1908- sold and missed.
1280- 2.3, FP 35R, E85, etc.
1135- 100% stock
'93 Mirage hatch- 4g63, AWD, etc (hoarding for build)

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TheBoz
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Galant VR-4 org Post #: 702060 posted 09/28/08 04:21 PM     Remind Me!  Send Private Message   Edit Post      
It is a full shaft. We were just doing all the testing on Rev 1, we will put a bead on it. But it held on just fine at 25psi, on a t67.

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CarRacer
Giant Sack of Ginger
83/2000


Galant VR-4 org Post #: 702066 posted 09/28/08 05:01 PM     Remind Me!  Send Private Message   Edit Post      
Peter Griffin and I agree, that's freakin sweet!

A very cool and unique mod, although I agree on lengthing the area for a coupler to attach or add a bead.

A great first effort for never making a TB before.



James
83/2000

Missed Shift | Auto News

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TheBoz
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Galant VR-4 org Post #: 702084 posted 09/28/08 06:34 PM     Remind Me!  Send Private Message   Edit Post      
Ya, keep the input coming. I want to make a lot of changes for rev 2. So anything you guys can think of that this needs. We used the BBK 75mm as our template for this. We did make a lot of little changes that would help to make mine a lot stronger and seal much better.

Also this was all done on a 3 axis milling machine. The only part we did with a lathe was the TB Shaft, and that was just to cut it down to size. The only lathe I have access to is from WWII so it is very loose.

I can tell you for sure that there is a lot more to a TB than meets the eye. The Butterfly was the hardest part, and getting it to seal up properly has been a huge pain in the ass.

Also Thanks for all the input so far.

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ktmrider
Cool Guy Crowd


Galant VR-4 org Post #: 702087 posted 09/28/08 06:59 PM     Remind Me!  Send Private Message   Edit Post      
Quoting CarRacer:

Peter Griffin and I agree, that's freakin sweet!

A very cool and unique mod, although I agree on lengthing the area for a coupler to attach or add a bead.

A great first effort for never making a TB before.


+1, maybe both ( longer and beaded ) on the input.
Still a beauty! Great job...



Mike O.
#464/1000 - Sold
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#86/2000 - Sold ( again )

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atc250r Galant VR4.org Moderator
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Galant VR-4 org Post #: 702088 posted 09/28/08 07:03 PM     Remind Me!  Send Private Message   Edit Post      
I'd have to agree 110%, make the flange for the TB inlet longer and either machine a bead into it or weld one there. How about putting a CTP switch mount for those of us that aren't baller enough to run an AEM EMS?

John



"...if they're so into masochism, they should just really go all out and start modifying Mitsubishis. And using them as daily drivers." - Mike R.

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turbowop
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Galant VR-4 org Post #: 702091 posted 09/28/08 07:06 PM     Remind Me!  Send Private Message   Edit Post      
Where does the FIAV and ISC go?

Looks good. +1 on a longer and beaded coupler section.



-Mark

A face only a grocery shopper could love.
1051

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TheBoz
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Galant VR-4 org Post #: 702095 posted 09/28/08 07:14 PM     Remind Me!  Send Private Message   Edit Post      
It is crazy because it is hard to decide what to put on and what to leave off. For me I dont need any of the fancy stuff , it is ok for my car to idle at 1300 rpm. However I would like to offer these up to the DSM community, but dont want to add a lot of features that people will not use.

I know I would love to have the Idle Control Motor and a BISS on there instead of using the Throttle body to set the idle.

The existing cupler mounting surface is long enough for a tbolt clap. How much more do you guys think it should be extended? (5mm, 10mm, 20mm)

Things to add
1. Idle Controller
2. BISS
3. Throttle Closed Sensor
4. Additional Cupler Mounting Surface with Bead

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chris
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Galant VR-4 org Post #: 702098 posted 09/28/08 07:18 PM     Remind Me!  Send Private Message   Edit Post      
thats bad ass! do you have access to a cnc machine all the time? and do you write your own code?


Edited by chris (09/28/08 07:19 PM)

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atc250r Galant VR4.org Moderator
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Galant VR-4 org Post #: 702110 posted 09/28/08 07:49 PM     Remind Me!  Send Private Message   Edit Post      
I would say 10 or 20mm added to the TB inlet would be nice to give the user some breathing room with it. I don't run a ISC or a FIAV on my car and IMHO, the majority of 4G63's that could benefit from a larger TB don't need them anyway. I only asked about the CTP switch because it does have a significant effect on idle and when coasting downhill. Without it the stock ECU won't shut the injectors off when coasting and the idle will usually surge for no apparent reason.

John



"...if they're so into masochism, they should just really go all out and start modifying Mitsubishis. And using them as daily drivers." - Mike R.

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turbowop
Hard Snarker
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Galant VR-4 org Post #: 702133 posted 09/28/08 08:38 PM     Remind Me!  Send Private Message   Edit Post      
The throttle body coupler in the pic below is a spare from a past setup I ran. It is 2.00" long. The one on my car now is 1.25" long, which is the shortest I would go comfortably. It leaves just enough room between the bead and the TB flange to clamp the coupler down.





-Mark

A face only a grocery shopper could love.
1051


Edited by turbowop (09/28/08 08:39 PM)

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Jonvr4
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Galant VR-4 org Post #: 702146 posted 09/28/08 09:19 PM     Remind Me!  Send Private Message   Edit Post      
That thing is pimp. Waaay over built, I love it.

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mean_green
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Galant VR-4 org Post #: 702245 posted 09/29/08 01:29 AM     Remind Me!  Send Private Message   Edit Post      
+1 on getting it done yourself...
-1 for the duralast...

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TheBoz
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Galant VR-4 org Post #: 702257 posted 09/29/08 01:57 AM     Remind Me!  Send Private Message   Edit Post      
LOL, duralast is mad tight JDM Yo!

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CarRacer
Giant Sack of Ginger
83/2000


Galant VR-4 org Post #: 702281 posted 09/29/08 08:30 AM     Remind Me!  Send Private Message   Edit Post      
One more thought, what are you using for a gasket? I'm sure people who would use this are going to have aftermarket manifolds, but the flange surface could still get damaged causing a bad seal.

I think NAPA sells flat sheets of gasket material, so it's possible to just trace and cut one out.



James
83/2000

Missed Shift | Auto News

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GIjoe
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1562/2000


Galant VR-4 org Post #: 702389 posted 09/29/08 12:55 PM     Remind Me!  Send Private Message   Edit Post      
wow, nice!



1991 Galant VR-4 1562/2000 SOLD as of 03/2016
1998 Subaru Forester
2011 BMW 1M

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TheBoz
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Galant VR-4 org Post #: 702419 posted 09/29/08 01:55 PM     Remind Me!  Send Private Message   Edit Post   
Quoting CarRacer:

One more thought, what are you using for a gasket? I'm sure people who would use this are going to have aftermarket manifolds, but the flange surface could still get damaged causing a bad seal.

I think NAPA sells flat sheets of gasket material, so it's possible to just trace and cut one out.




Yep, some cut out pepboys gasket . As long as it holds boost that is all I care about.

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