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I've been talking about this for awhile now, and finally got a chance to actually start the project last week. As I mentioned in my previous post http://www.goldwingfacts.com/forums/forum4/120779.html my goal is to avoid tearing down the bike for as long as possible so I can take advantage of the remaining nice weather to enjoy it. So, I needed to start with something that doesn't require me to tear it down. Since I need to fabricate an intake manifold for this project, that seemed like a good place to start.

I've been buying bits and pieces here and there for awhile now and have accumulated quite an assortment of parts already. Some I'll be able to use, and others I won't. But the only way to find out for sure is to buy the part, and check it out. A prime example of this is the intake manifold from a GL1800. It won't fit. But, interestingly enough the port spacing on the heads is exactly the same as the GL1500. Excellent! This means I'll be able to use the GL1800 fuel rails! I'll should also be able to use the injectors, and throttle bodies as well as the regulator and all the fuel lines from the 1800. The jury is still out on the fuel pump as I haven't had a chance to compare the two.

Here is a shot of the GL1500 intake gasket sitting above the GL1800 intake gasket. The GL1800 ports appear to be a bit bigger when looking at this gasket, but in fact they're pretty close to the same size. 1.1" on the GL1800 is what we measured, while the GL1500 measured in around .96"




Here is a shot with the GL1500 gasket sitting on the GL1800 intake manifold.




** Disclaimer ** I should make it perfectly clear that I am NOT a professional. While I do have some mechanical background, I do not have access to a machine shop and up until last week had never in my life welded two pieces of metal together. The welder I have access to is a very basic unit that doesn't have any provision for gas. So, while I do believe I've done a decent job, it isn't pretty. But then again, neither am I! :raspberry:
 

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Ok, so it's off to the races! The first thing I needed to do was build the intake flanges. I used a piece of 4"x3' 3/16" piece of flat steel that I bought at Lowe's. (in fact all of the steel I used for this project I bought at either Lowe's or Menard's) I used an old intake manifold gasket from a GL1500 engine that I bought to use as a jig for this project, and traced it out on my steel.





Then I cut the two pieces from the steel.




Next up is drilling. I did a lot of drilling :action:
 

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I do have access to a drill press, and it made things a lot easier. Just mark the center of the holes, and be VERY careful to be sure the center of the drill bit starts where the lines cross... (FYI: the laser cross-hairs are pretty much worthless.) And, yes, I used a hole saw.











Here is a shot with all the runner holes drilled.





Next up is the mounting holes..... and test fitting.





 

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OK, so here is the part where I start cutting and grinding metal. It sure would have been nice to just have a machine shop cut these out for me, but that would have been too easy. This is also where I was in the project when I found a big lump on my back tire. (just happened to be walking by the bike, looked down at the back tire and something definitely wasn't right!) I lost the better part of two days because of this. I ended up removing both front and back tires, replacing the rear brake rotor and doing a complete brake job on the bike as well. I also added baffles to my exhaust while I was at it. This improved things a lot, but I'm still thinking I may go ahead and try the GL1800 mufflers before I do the EFI conversion.


Ok, enough of that, back on topic.


Here's some of the ugliness as it was happening!













 

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Not the prettiest, or most precise pieces in the world, but functional. And, hey, once this is completed it's going to be under a bunch of tupperware for it's entire life and no one will really see it anyways.

From here it's time to start thinking about the runners. My first plan failed miserably and caused me some alarm. I had a hydraulic bender (piece of crap) and thought that I could bend 1" electrical conduit for the runners. Well, the bender wasn't up to it. (or I wasn't up to it... Hey, I'll admit it....) Kinks, dings you name it. Well, luckily I found out that I could buy pre-bent 1" electrical conduit at Lowe's for only 3.48 a piece. I just about cleaned them out.



So, I took one piece of conduit and placed it next to the original GL1500 manifold on the edge of the bench for comparison. Marked my spot and used a miter saw with a cutoff wheel attached to it to make the cut.


Here's my not so scientific method for making the rest of the runners...




And here's all six runners with the two mounting flanges










Next up, joining everything together on the motor and fabricating the box.
 

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I got the bright idea here of using a 1" wooden dowel to line up the center runners. Figured I'd tack weld them in place and then cut them to length later. It actually worked out pretty well.











I also fabricated the ends of the box that the runners go into at this time.




 

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Ok, here's where it really starts to get ugly... My first attempt ever at welding.








And now, test fitting the other runners...












Now the other side, and removing the tacked on pieces for welding and yet more grinding! :action:






Some closeups of the welds....




After some grinding.....


 

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I may get picky and do a lot more grinding to make things look nice. At the time I was doing this I knew my allotted time was running out, and I wanted to get as far as I could before I had to leave. (long haul truck driver) So, I put the grinding on the back burner for now, and started fabricating the box. I only got the bottom done, and the top piece is cut out, but no holes yet for the throttle body mounts.








And here's the final shots with the top piece just sitting on it to give you an idea of what it'll look like when it's done. I am going to do some research into intake manifold volume, and how it effects the operation/performance of the motor. Right now I'm thinking that there will be dividers welded into the box to reduce the volume to as close to stock as I can. But, that may change after I do some reading....









And, that's it for now. It'll probably be another month or so before I get a chance to get back to this.

Just remember, what I lack in skill, I try to make up for in determination! :action:
 

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Very interesting thread, and apart from the welding issues (probably still looks better than mine) you're doing quite a fab job. Looking forward to seeing more.

On edit, one thing that comes to mind is the length of the intake runners. I've never seen an 1800 intake but I'm wondering if the long runners will cause problems @ low rpms.

Steve
 

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Actually, the runners really aren't much longer than the stock GL1500 runners. Here's a photo I took with the GL1800 throttle bodies sitting on top of the engine before I took it out of the truck. If not for the offset of the two manifolds, it's only about 1/2" or less from fitting. The box on the other hand has a lot of volume, and I do plan on reducing it with dividers. I also don't trust my welding to be 100% air tight, so I'll be coating the inside of the box and the welds on the flanges with epoxy. Then I'll paint the entire outside of the manifold with POR 15 which should finish sealing things up.









Doug
 

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Got my attention!!!!



Awesome job!!



Keep it coming when you get back. I am eagerly awaiting your return.



Tim.
 

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Looks good.one thing comes to mind is the gl1500 and the GL1800 manifolds are two piece,will you be able to install your one piece manifold?
 

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Looks good.one thing comes to mind is the gl1500 and the GL1800 manifolds are two piece,will you be able to install your one piece manifold?

Yeah, I've thought about this too... Actually, the GL1800 manifold is one piece. (two manifolds, but only one piece. If that makes any sense...) But the answer to your question is yes. I'll be able to do it even if I have to drop the engine. I'd rather not have to go that far if it can be avoided though.... Come to think of it, both sides will be separate from each other so worst case scenario, I could always cut it in half.... No... I couldn't do that.... It'd be kinda like taking sandpaper to a new paint job.


GL1800 manifold:


 

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Great job you have done.

Got my interest for sure. I have always loved EFI because of the way it just "starts and goes".

Anxious to see more when you get back from OTR.


Pinned this to the top of the page so it don't get lost.
John
 

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:waving:



Very interesting job fer sure!!!!

How are you going to mount the injectors???



Too bad an adapter can't be put between the 1500 head and the 1800 manifold.



Have you thought of using one throttle body on your intake box??



Definately a lot of engineering going on here....



Smooth sailing..... John/kb0ou
 

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It looks like your definately on your way.;)

The picture of the thottle body to the manifold also answered one of my questions.



I am curious on where you are going to put the injectors.





Great job and much better than I could do.:thumbsup:
 

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Too bad an adapter can't be put between the 1500 head and the 1800 manifold.
Very interesting idea John. My friend and I had discussed the possibility of doing an adapter for the 1500 manifolds to fit the GL1800 throttle bodies. But I wasn't keen on the idea. My friend may have mentioned this, but I probably wasn't listening as closely as I should have been at the time. At first I thought there would be offset issues. But after looking closely at some photos, it might be possible. I even have an idea how I could do it. The problem is that unless you cut the manifold it will block off access to your spark plugs. Not completely, but probably just enough that you'd have to remove the manifold to get them out.

** Correction ** I just looked closely at the photo where I laid the intake gasket from the 1500 over the manifold for the 1800 and it would pretty much completely block access to the spark plugs. Cutting the manifold would make zero difference because the fuel rails and where they mount to the manifold would be in the way. You can't cut those....


Have you thought of using one throttle body on your intake box??
Actually my goal was to use as much as possible of the GL1800 system. The one drawback I see to using a single throttle body is that you then have to join both sides of the manifold to form basically a single plane manifold. This effects engine performance. It may not be all that bad, and it might even be good. I just don't know. One advantage that I can see to doing this is that you wouldn't ever have to worry about balancing your throttle bodies. But then again, I could join both sides of the manifold with my current throttle bodies and I still wouldn't have to worry about balancing them. In fact, I'm not even sure there is a way to balance them. I did read something in the service manual about not turning the screws with white paint on them because it would throw the factory balancing off. But I haven't really read the manual in depth.

I am curious on where you are going to put the injectors.
My first inclination is to drill the runners right above the intake ports in the head. Cut my injector bungs to match the curvature of the runners and weld them in place shooting straight down at the intake valve. There might be a clearance issue with something else on the bike though. (Frame, ducting, tupperware, etc etc....) So, this is something that I'm going to have to look closely at, and probably dis-assemble the bike some to figure out.

I do have a backup plan, but I'm not as happy with it. There is a lot more room under my manifold because it takes up less space than the stock cast manifolds. That, and the fact that there is some tubing that will likely be removed, should leave me enough room to drill into the underside of the runners right above the flange and put my injectors there. Unfortunately, the injectors would no longer be shooting straight down at the intake valves. I believe this would work. But, it's less desirable in my opinion.




Doug
 

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Great job and will be watching for up dates
 

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Not a mechanic eh?? :cool:Remind me not to EVER get in a game of Poker with you!!!!:shock::shock::cheeky1:



For not ever having welded, those actually look pretty good!!One thingI would suggest doing is to leak test the welds on each pipe. After a bit of thought, whatI'd do ismount each intake rack on the apropriate head, rig an air fitting to screw into the spark plug hole, and cap the pipe ends with one of the aftermarket rubber car engine block freeze plugs that expand when you tighten the nut on the outside of the plug.



Rotate the engine till the intake valve is open then apply about 2-4lbs of air pressure and check the welded area with some soapy water. Mark any leaks with a soapstone for touch up welding,and then repeat for each pipe weld....



Otherwise you might have to chase a vacumn leak after everything is installed!!:shock:



It look like a fantastic job you've doneso far though!!!:coollep::coollep::coollep:
 

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How are you going to control the fuel flow and sequence on your injectors?
 
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