Intake manifold design - Steve Saunders Goldwing Forums

 
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post #1 of 7 (permalink) Old 09-15-2008, 10:49 AM Thread Starter
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Post Intake manifold design

Hey to all, I have just finished rebuilding my weber DGAV 32/36 carb for conversion to single carb on my 1200. I found a few threads for jetting and have basically brought it back to the stock configuration, I am trying to design/ build an intake for it any idea's? I was going to use a porsche 914 plenum and runners but I couldn't find one. I am thinking about sheet metal and thin steel tubing, I can weld the whole thing together but If I use aluminum I would have to jig everything and have my neighbor tig it together. ANy recommendations, I will be heating the intake with coolant which brings me to another point, I can weld tubing to the plenum and runners to heat it but using aluminum will present another tig job for my neighbor and I don't think i have built up enough favors for that!!!! I figure I would use the same size tubing as the intake "elbow" from the original carb setup but I am not sure of that either. Any info on intake design for single/2 barrel carb setup would be great. Thanks

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post #2 of 7 (permalink) Old 09-15-2008, 11:03 AM
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Use exhaust tubing the same size as the rubber manifold inlets on your bike. Mine was made using 4 "J" bends cut and welded together. You don't need to heat it if the carb is the right size. I used an old 1500 Volks Beetle carb. It doesn't sweat or freeze up and runs great. Mine is an 1100 but the 1200 isn't much if any different.

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post #3 of 7 (permalink) Old 09-15-2008, 11:13 AM
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stinkyfartur

I've been putting a materials list together in my head and was concidering using copper plate and plain old copper tubing for coolant heat.
Copper is easy to cut and solder with tools I already have.

Another idea is using plastic.
With the wide selection of glues available, that too is easy to assemble and plumb.

Anyway, just kinda thinking out loud.

1983 GL1100 Interstate with 1200 engine, single carb, and C5 ignition.



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post #4 of 7 (permalink) Old 09-15-2008, 11:31 AM
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When I got my Weber equipped Aspencade, Raymond gave me this manifold setup to try someday. It fits a Weber carb perfectly, and it has the 4 runners you can hook. However you can, it's up to you. But a good start.

Pretty small, but looks efficient. If you need more pics, I can take a pic of mine tonight.

Here on Ebay

You don't have to use the tubes supplied, but the manifold looks good.

1997 GL1500 SE Pearl Sapphire Black
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post #5 of 7 (permalink) Old 01-25-2009, 11:30 AM
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I have a 1981 gl1100i that I'm making a manifold that replaces the air box and carbs using the head elbows. I have access to mill and lathe plus I TIG so I have and advantage here. I'm using a Weber 32/36 dvg carb, after it in I'll figure the correct jetting using air/fuel ratio meter. I think the main issue will be at idle may possibly need to go down one or two jets. But I'm attemting to keep the installation simple slip into elbow boots tighten clamp. Ever need to put stock carbs back in simple matter to do. But this is half the fun of an old wing.

Tell me it can't be done and I will make it happen if I can make or get the parts made
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post #6 of 7 (permalink) Old 01-25-2009, 12:13 PM
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Been running a 2 barrel Holley on my 1100 for about 4 years now . Made the intake by converting the original airbox into the plenum. It's not pretty but it was super cheap and has held up well. The Holley was super cheap and has really brought the bike back to life after fighting the original carbs for years... Feel free to check it out: http://www.htc.net/~squirts/plastic.htm


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post #7 of 7 (permalink) Old 02-03-2012, 10:56 PM
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mainwiz3 wrote:
Quote:
I have a 1981 gl1100i that I'm making a manifold that replaces the air box and carbs using the head elbows. I have access to mill and lathe plus I TIG so I have and advantage here. I'm using a Weber 32/36 dvg carb, after it in I'll figure the correct jetting using air/fuel ratio meter. I think the main issue will be at idle may possibly need to go down one or two jets. But I'm attemting to keep the installation simple slip into elbow boots tighten clamp. Ever need to put stock carbs back in simple matter to do. But this is half the fun of an old wing.
mainwiz3, I see you're online right now.

What ever happened with your 1100 single-carb project?
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