Hooking up the braking system to the throttle bodies.
To create a feed for the brake system I chose to use the stock fuel injector positions in the bodies as I intended to run my fuel injectors in the stock locations on the manifold.
A standard steel AN fitting was turned down to provide
an interference fit with the fuel injector ports on the
bodies. The centre was also bored out to 8mm to allow
for greater flow.
The adaptors were then pressed very carefully into the
bodies, and held in place with a high strength thread
locking adhesive.
To provide clearance for the female part of the fitting
to be screwed on I machined out a portion of the
actuator rod for the idle jets. It transpired that i
would not be using the stock idle arrangement so the rod
can be removed instead.
Although I had originally decided to use 90° fittings to couple up to the bodies and run a pipe from each back to a vacuum chamber I was looking at the stock Fireblade fuel rail, and thought I could make a neater job of it that way. The easiest way to do this would have been to simply turn up an adaptor to take place of the fuel injector and keep the rail mounted to the bodies with the standard brackets, but I could not do this because the rail protrudes beyond the back face of the bodies, where intended to mount my air filter base plate. Because of this I needed to move the rail closer to the bodies and re-think the mounting.
Stock Fireblade fuel rail protrudes beyond the inlet.
I turned down some more fittings that would be pressed
into the stock fuel rail. The fuel pressure regulator
mount was trimmed off & welded over along with the
original fitting for the fuel supply. A 90° brake servo
hose barb removed from a stock inlet plenum was welded
on.
As before the machined fittings were turned down to an interference fit, pressed on carefully and held in place with thread locker. They were turned so as to broach the mounting bucket on the rail when pressed in - this worked very well.
I now had two options for attaching the brake servo, using individual fittings and a vacuum chamber, or a single common rail. This also gave me flexibility when it came to the idle system as I could always adapt this setup to perform idle control if required without having to alter the throttle bodies. Also, I have the option of capping off the ports with blanking caps.