Making some SAI block offs. Anybody want some?

[W201028]

Title makes it clear, I'll be machining some secondary air block off plates in the coming week for my project GS.

If I'm going to go through the trouble of setting up a machine, I may as well make more than two! So Ill take orders on this topic page, and will post again after I have milled them. Payment can be worked out via PM, after I have some pictures of the finished product of course. Im thinking $15 American for a pair, via Paypal only. This is enough to cover material cost, shipping, and a little of my time.

They will be CNC milled from either 7075 or 6061 aluminum billet to a size matching the factory SAI flanges, just without the center hole ofcourse. Same thickness so factory nuts will be reused to attach them, you'll just need to buy or make your own gaskets. Black RTV is what I will be using, should hold up fine.

I plan to engrave GS into the center of each one, approx. .015" deep so the characters will be about .03" wide. Not sure on the font yet, drew this in Sketchup but will be programing in Mastercam so the same font might not be available.

Also, if the response is overwhelming, I may not be able to get to everyone. Probably cant make more than 20 pair due to the fact this this will be a government job in an otherwise fully operational machine shop.

Unfortunately I cant seem to attach a picture of the model I made. Ill try again later.

Reply if interested!

[user11235813]

to post an image upload to https://postimage.org then choose the 'direct link' paste it here between the 'image' tags.

Code Select Expand

[img]direct link here[/img]

btw what is an SAI

[W201028]

Secondary Air Injection; air tubes that go to each exhaust port and inject fresh air for the purpose of burning any un-burnt fuel coming out of the combustion chamber. Its an emissions system, and like most, unnecessary for the operation of the engine. Im sure it hurts the hippies, but alot of people remove and blockoff this system.

I dont know of any major company that sells block off plates, so I decided to make my own like many others have. I dont believe that removing the system will increase horsepower, nor am I trying to pollute more. Just getting rid of clutter under the hood, so to speak. Plus, without an airbox, theres nowhere to hookup the SAI intake hose.

Anyway, heres a picture of the model. I was forced to upload since the attachment wont work.

[user11235813]

OK thanks. Have you considered making a fork brace for the GS I think there'd be plenty here who'd go for that. Current options are way too pricey like $180 from racetech. Buddha used to make and sell them but he sold out and no longer makes them. No one would begrudge you a reasonable profit either.

It wouldn't have to be fancy, just something to replace the wafer thin one already on the bike.

[W201028]

That is on the list of upgrades for me, I have a plan on how to make on with a milling machine. Thats a part best suited to water jet, but could be done any old way. Like I said, I work for a machine shop, I dont own one. The owners dont mind a government job but moonlighting with their equipment and electricity is frowned upon.

The SAI plates are only because I am going to CNC them anyway, so I may as well make a few more while Im setup. If I do program a fork brace, I will let everybody in on that too, again on a limited basis. There are alot more parts I need to make before the brace though, so bear with me.

[user11235813]

The beauty of making anything for the GS500 is that there are gazillions of them same with the S40 Savage. Donate the profit to your work christmas fund or something if that sweetens it for them. Anyway do keep it in mind because it's love that makes the world go around, in this case the love of the gs.

[ShowBizWolf]

I love threads about custom GS stuff... very neat!!

Don't forget about these two options right here on the forum for the heavy duty fork brace:

http://gstwins.com/gsboard/index.php?topic=67475.0

http://gstwins.com/gsboard/index.php?topic=58455.0

I got the one from chuck because I was too impatient to wait for enough people to order from the other thread  but I do believe ATM they both have the fork braces available.

(Most certainly do NOT mean to threadjack... just wanted to share those links in case either of ya guys really wanted an upgraded fork brace)

[user11235813]

Thanks Wolfy, this is exactly what I've been looking for, I thought they were all finished.

[rabies]

I will purchase a pair please. Pm info and I will paypal the $ as a gift. THANKS!

[W201028]

Cool, I'll put you down for a set. I only grabbed enough material for four sets since there doesn't appear to be much interest,three are spoken for, so one set left if anyone wants it!

[ringading57]

Hi  i would like a set too , but i'm in the united kingdom would you post to there ? , thanks

[W201028]

Sure, but I would have to charge a little more, since international shipping is going to cost a bit extra. How's 20$ American sound to you?

[mihkels]

Care to elaborate what these plates do and how to install them? What model years do they fit?

Thanks!

[ringading57]

$20 sounds ok to me

[W201028]

Ok, parts are all milled and deburred. Heres a pile of them on my granite plate.



And I installed my set onto my filthy motor. Let it be know that adding nice shiny aluminum to a nasty motor will make it look even nastier.



So thats the product, and they will arrive unpainted as shown in the pictures. Ofcourse you can finish them yourself with some high heat engine enamel, or just leave them in the raw. I am biased, but I think they look great!

Pms will be sent with my paypal info, if you three who responded are still interested in the purchase of a pair. If paid by Saturday they will be at my local post office that day. Thanks for the interest everyone!

[ShowBizWolf]

Wooooo boy do those ever look nice!! Awesome work W201028 

[W201028]

Thanks wolfy, several more billet parts to come, although those wont be made in batch for sale. They are more complicated and sort of custom made for my project. I will start a build thread when I get enough parts together to make it worthwhile. Those who ordered a set, I am going to the post office tommarrow morning to ship them out, except for you dave!

[dwidrick]

I will take a couple please. PM me and I will be able to paypal you. Thanks!

[JovianJustus]

I would like a set of these as well!

[W201028]

Sorry guys, all are sold and shipped. I really didn't make any money off it either, only about 20$ after shipping them out. In the three hours I spent programming, setting up, and milling them, I could have more than tripled that just staying at work for 3 hours. It's no wonder the companies that make these for other bikes charge twice as much.
But I am proud to have supported the GS community for at least three other riders out there, especially the one in Great Britain. It's nice to know something I made will be rolling around across the pond.
If anyone else is dead set on a pair, I would happily upload an image with dimensions, and if you have any machinist friends they could make you a pair easy.