More Intake Progress

I have the throttle body adapted to the manifold in what I presume is very nearly final form.

The 95% completed adapter plate is the key to making this very nearly a bolt on conversion.

Sharp observers will see that I drilled the two inside holes incorrectly the first time. I had my template placed wrong. Luckily, there was still plenty of metal to thread into, though running the tap though was tricky. I had to run it forward all the way through and pull the shank of the tap though the back side of the hole. Attempting to turn it out backward made the tap cam into the erroneous hole and jam.

To truly finish the plate, I need to weld on a brace fro the throttle body, media blast the entire assembly and paint it with something fuel-proof, probably epoxy.

As a side note especially for anyone wanting to use this throttle body, get the stock mounting boots and O-rings. In my opinion, scratch fabricating something to fit is just not worth the effort. They are about $20 apiece from Kawasaki [part no 16065-0024]; I paid $20 for the pair on eBay. One online Kawasaki parts house sells the O-ring for $4.71 each, but I found an excellent equivalent O-ring at AutoZone for $0.99 each, FelPro part number 35087. It happens to be for the water outlet for a 91-95 Saturn 1.9L. Beware, however, my AutoZones tend to stock only one per store, so I had to go to two stores.

As for the rest of the intake manifold assembly, I have not placed it on the trike yet, but I have mocked it up in the level mounting position to see what the angle of the all components will be. As luck would have it, the rearward angle of the manifold and the rearward angle of mounting boots are the same, or at least close enough that I can’t tell. It remains to be seen whether I will have the throttle bodies mounted as shown or flipped around so the throttle cable approaches from the front.

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