Bax Cave Winter Project..........

[Bax]

COVID keeping me close to home so the XS getting modernized this Winter..... More to follow.

[cajun31]

I will definitely be watching you on this one.

[DiverRay]

You have my interest as well! I am trying to use a megasquirt on the '78, but that unit looks a LOT nicer than the used GXR stuff I have.

[Bax]

Small progress on assembly this evening. Going with appropriately sized at, 80% duty cycle, 215cc/min injectors. Genuine Magneti Marelli IWP048 injectors are out of production and seem to be targeted by made in China knockoffs. Good stock still exists with Vespa and MotoGuzzi for a source of the M M brand.

Installed injectors in the TB array tonight.

[Bax]

[Bax]

Finally got through the madness of projects and equipment recovery from the holiday manufacturing shutdown at work. Got some time to advance the modernization of the XS today. Just doing a bit of fitment planning and drafting up the intake manifold transition. A few pics to share.

[Bax]

Fitment check with the gas tank. Seems so far that my planning is not revealing any unforeseen interferences.

[Bax]

My buddy 3D printed me up some transition manifolds today that I'll use for fitment verification before expending $$ for custom Aluminum parts. I expect to have some time to set in place on the bike tomorrow, I'll update accordingly.

---Bax

[Bax]

January in NH = cold makes the rubber boots hard...... Did the fit to the air box today and it seems like the same position as with the Mikuni's. I'm going to grab the borescope tonight and see if the gap inside the boot is closed up and go from there. I'll post a pic of that view not often seen later.

---Bax

[2WheelFun]

Looks great, not sure why you would get it machined out of aluminum. Nice to have friends with 3D printers!

A couple of minutes sanding and painting then call it good to go.

[Bax]

Looks great, not sure why you would get it machined out of aluminum. Nice to have friends with 3D printers!

A couple of minutes sanding and painting then call it good to go.

The printing may look decent in the photo but it is definitely not flat on the flange face and quite out of round on the openings. With machined Al I can ensure good tolerances, add in a good o-ring seal between the flanges, and not worry about cracking.

---Bax

[cajun31]

looking good. When will you finalize the kits and how much will they sell for? Just kidding.... but might be something to think about.

[Bax]

Internal check showing an expected step down lip on the engine side intake, which I'll cut down to a smooth chamfer with a taper burr when I pull the head. The filter side boot insertion seems to be a bit short with a noticeable gap. My air box is all the way forward on the mounting screw slots and the OAL length is identical to the Mikuni so I'm a bit surprised at this. I do have sets of replacement boots on both ends so there may be a bit of minor dimensional differences adding up to cause this gap. Easy to add a few mm in CAD model.......

---Bax

[DiverRay]

I would add extra to the model, and machine after if needed. You may also look at putting a "bend" in the adapter, so it ends up the lat 20mm level on the bike, not pointing up.

[Bax]

I just looked at one of my original air box boots and it evidences that this gap has persisted with the Mikuni carbs for some time. Never noticed the airbox boot not mated fully to the stop on the carb body tho.?.?. Oh well, added 4mm to the part model and moving along.

Bax