First
Template
The whole project kicked off with the creation of a simple replication of the block's mounting points and crank centerline.
The Mule
This photo array shows the progress from the plexiglass to piece de resistance.
Particle
Board Mock-up
Extremely crude adapter that served to establish the fore-and-aft interface between the crankshaft and transmission input shaft, and verify flywheel/starter relationship.
First
In-Car Measurements
Engine and tranny positioned to define initial pan-configuration, engine mount design, exhaust manifold space, and head-to-engine-bay-rail clearances.
Job
1
Fabulous KL crankcase layout created serious difficulties for oil pump and pan design.
Job
1 (continued)
Another excuse to go with manual steering, no?
Job
1 (continued)
Street Modified rules (as of 2006) don't allow subframe redesigning, so we will make a low-profile pick-up tube to supply the pump.
Job
1 (continued)
Pan depth will have to make up for small horizontal area. (Ground clearance ended up @ 2.5".)
Not
Much Room For Headers
We could use pre-94 manifolds on a street version, though.
Looks
good in there, though...
Even with a 3/4" adapter, the engine has an additional 3" of space to the radiator!
Add
Some Heads And
... it is to marvel.
Proper
Long-Tube Stainless Headers
Happily, I got a firm quote for the construction up front, so the many additional hours reality required were chalked up to experience by Ken, the righteous proprietor at D&D Fabrication.
Headers
In Situ
Yep, it's tight.
Ultimate
Intake Takes Shape
Being a long-time Suzuki Man, these GSXR throttle bodies belong here. The manifolds were designed by Steve @ Progressive Automotive ("Cylinder heads our specialty").
At
Long Last
Installation begins.
At
Long Last (continued)
A precision fit, but...
At
Long Last (continued)
Let the teething problems begin!
Dyno Day I
An excellent start.
