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Discussion Starter · #1 ·
well this is something ive been working on for a little while. basically i want to use the ITR intake manifold on the GSR head. why? well cause i want to race H1 Honda Challenge one day and their rules say you have to have a stock unmodified intake manifold. and im building my engine to HC specs so obviously ITR is the best choice. originally i planned to use this plate to adapt the coolant ports, but i decided not to do that and ill exlpain why later. the plate is 3/8" thick 6061 Aluminum.

i got the plate and used the hondata gasket as a stencil to drill the mounting holes. aparently the hondata gasket sucks balls as a stensil. i guess it doesnt have to be perfect since it just gets pressed on by the manifold. i had to fudge the holes a little bit but i got them all lined up now and it fits tight on the head which is all that matters.


next i lined up the intake manifold gasket with the hondata gasket to drill the correct holes in the ITR gasket. holes drilled and on the head to check fitment. perfect :)



now i would like to say something about drilling the holes. in the very little bit of information ive found about doing this (ITR mani on GSR head) it said that the bottom holes were the only ones that lined up. this isnt entirely true. they are the correct spacing yes, but they are a different distance from the ports. meaning that if you mount the ITR mani on the gsr head without reaming the bottom holes lower, the mani will sit too low and most certainly interfere with airflow. so when i lined up the gaskets to drill holes i made sure to base everything off the PORTS. if anyone out there attempts to do this, i cant stress this enough. dont fuck up your airflow for the sake of it being easier. its not even that much more work to do.



now another thing to note is that im going to abandon messing with the coolant ports. mainly cause making a passage through this plate would be too steep and very difficult to cut. to really be able to adapt them you need a thick plate, probably thicker then 1/2" and IMO thats too thick. so screw it. theres really no point in having that bypass anyway, its to help out in cold weather but my racecar never gets run in the winter. besides its less heat soak. now you may ask, why even bother with the plate? well besides the fact that im still adapting port shape, this is why...



the ITR mani doesnt even cover the hole on the gsr head. so the plate (along with a hondata race gasket) will cover the hole and keep any coolant from leaking out. plugging the hole isnt really an option as theres not enough material on that wall to hold threads. and im not welding it up. i really dont want to mod it at all. in case i ever want to sell it.

next thing i did was bolt everythying up to the head. one cause i wanted to see how everything looked. and two i needed to trace the ports for the ITR. seen below



and here it is with the ITR ports traced and the GSR outline traced. ready to cut.



now all i really have to do is cut it out, then screw with the port shape on the GSR side. and it will pretty much be done. i aslo have enough metal left to make another one, so ill probably do that and sell it or something. ill update as things progress :). probably wont be for a few weeks since most of my tools are in baltimore. i dont have what i need here to cut the amount of material off that i need to at this point. let me know what you think :)
 

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yours looks a lot less complicated than mine

I want to use the ZC manifold on an Si head... nothing lines up, not even close, except for the ports
 

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Discussion Starter · #4 ·
rex2nr said:
yours looks a lot less complicated than mine

I want to use the ZC manifold on an Si head... nothing lines up, not even close, except for the ports
as long as the ports line up, thats all that matters., just match the gaskets up with the ports, mark where to drill holes, and viola you have a mani that fits. hows the coolant holes line up? as you can see they arent even close on my setup. hence why im just blocking it off.
 
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