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Discussion Starter #1
Backstory:

Problem #1:

If you have turbocharged or supercharged your Vrod you may have noticed there are NO shaft seals in the throttle body. "So what! I have been running my turbo/supercharger/leaf blower for years this way", you say.

Indeed! You also are venting boost to atmosphere when it should be going into your engine (and not a little bit by the way).

Why did Harley NOT include seals? Two reasons: Cheap and no reason for an engine that was never designed to see forced induction.

Problem #2:

It's been well known (I have lost count of how many stories/tales of woe I have read about this issue) that stock throttle body shafts are a problem. They don't capture the plates (the butterflies mount on the shafts, not between a slot/captured). Carsten from Holy-Moto (now defunct) created the solution to this by fabricating shafts with a wire EDM'd slot in the center to capture butterflies as previous vendors attempts at welding screws did not solve the issue.

YES this has been reported even with stock cams. It really gets exacerbated when you use cams such as the SE2 cams from the MoCo. Supposedly not so much the case with Jones cams, but none the less the stock design of the shaft is anything but safe (ask the unfortunate soles that had an engine eat a screw).


The Solution:

I have been working with a local and very high end machine shop to perform the following:

  • Install lip seals on ALL points of boost leak/areas that need sealing: This includes not only the sides with bearings, but the other side where the shafts go through a bushing. This WILL solve the boost leak issue permanently. This is not a "remove shaft and install magic seals that fit" solution. It requires precision machining and very small seals (that were horrific to source). It looks OEM (and frankly should have been there in the first place, however cheap rules the MoCo) and will function as such (the bearings are replaced with brand new ones during this process).
  • Create essentially a copy with a few improvements of the old Holy-Moto shaft design (once again, a captured/wire EDM'd style shaft).
The Bad:

This kind of custom machine work is not cheap (especially in the volume, or rather lack thereof, that Vrods command).

I am going to post pictures of the finished product in about a month. My plan is to offer this as a mail-in service (or possibly core based if I can get a few throttle bodies in hand).

I'm planning on an initial run of 50 shaft sets (this might change as it's costing me a pretty penny or 10 to get these made.....).

The throttle bodies will NOT be offered in a bored out/larger option. I don't think they are necessary for anyone but big bore/drag strip used Revos (argue away, I don't care for big bore options...only forced induction when it comes to this bike).

Turn around time will be likely a month unless I can get some cores in hand and get a few pre-made on the shelf. However, unless interest is decent I'm not planning on anything but batches to be produced. At the current moment that's equal to about 1 month turnaround.

Soooooooooooo.....if this interests you, let me know. If it doesn't, OK! I'm not posting this to argue facts or opinion, just offering up a solution to a problem that no one has really solved in all these years.
 

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Discussion Starter #3
Sounds like something my engine could benefit from, I have a spare throttle body
I'll let you know when I'm ready to get it in progress. I've been drawing and running back and forth to the machine shop for 2 months now. Glad to finally get this (and another much larger project) put into reality.
 

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Discussion Starter #7
Interesting! Keep us updated, V-rod world needs people like you. (y)
Much appreciated. Sometimes I think I talk to myself due to the low volume on this forum. Most of my "ideas" are literally personal projects that friends convince me to market. I've got some fairly wild stuff coming from my shop, I just need to finish drawing and get the CNC shop busy (that and open my wallet).

For anyone that cares...I bought a HUGE 3D printer over the winter to speed up development. Such a game changer. No more CAD....go to machine shop....create an ashtray....kick and scream about wasted cash, redraw/repeat. With the 3D printer I literally draw, print, hold up to the bike, keep on going. If only PLA was acceptable for actual parts...ha!
 

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Backstory:

Problem #1:

If you have turbocharged or supercharged your Vrod you may have noticed there are NO shaft seals in the throttle body. "So what! I have been running my turbo/supercharger/leaf blower for years this way", you say.

Indeed! You also are venting boost to atmosphere when it should be going into your engine (and not a little bit by the way).

Why did Harley NOT include seals? Two reasons: Cheap and no reason for an engine that was never designed to see forced induction.

Problem #2:

It's been well known (I have lost count of how many stories/tales of woe I have read about this issue) that stock throttle body shafts are a problem. They don't capture the plates (the butterflies mount on the shafts, not between a slot/captured). Carsten from Holy-Moto (now defunct) created the solution to this by fabricating shafts with a wire EDM'd slot in the center to capture butterflies as previous vendors attempts at welding screws did not solve the issue.

YES this has been reported even with stock cams. It really gets exacerbated when you use cams such as the SE2 cams from the MoCo. Supposedly not so much the case with Jones cams, but none the less the stock design of the shaft is anything but safe (ask the unfortunate soles that had an engine eat a screw).


The Solution:

I have been working with a local and very high end machine shop to perform the following:

  • Install lip seals on ALL points of boost leak/areas that need sealing: This includes not only the sides with bearings, but the other side where the shafts go through a bushing. This WILL solve the boost leak issue permanently. This is not a "remove shaft and install magic seals that fit" solution. It requires precision machining and very small seals (that were horrific to source). It looks OEM (and frankly should have been there in the first place, however cheap rules the MoCo) and will function as such (the bearings are replaced with brand new ones during this process).
  • Create essentially a copy with a few improvements of the old Holy-Moto shaft design (once again, a captured/wire EDM'd style shaft).
The Bad:

This kind of custom machine work is not cheap (especially in the volume, or rather lack thereof, that Vrods command).

I am going to post pictures of the finished product in about a month. My plan is to offer this as a mail-in service (or possibly core based if I can get a few throttle bodies in hand).

I'm planning on an initial run of 50 shaft sets (this might change as it's costing me a pretty penny or 10 to get these made.....).

The throttle bodies will NOT be offered in a bored out/larger option. I don't think they are necessary for anyone but big bore/drag strip used Revos (argue away, I don't care for big bore options...only forced induction when it comes to this bike).

Turn around time will be likely a month unless I can get some cores in hand and get a few pre-made on the shelf. However, unless interest is decent I'm not planning on anything but batches to be produced. At the current moment that's equal to about 1 month turnaround.

Soooooooooooo.....if this interests you, let me know. If it doesn't, OK! I'm not posting this to argue facts or opinion, just offering up a solution to a problem that no one has really solved in all these years.
*Souls.......
Jus sayin.......
 

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I have edm machine at my work and made slotted shafts to my 58mm TB. Shafts are silver steel EN 1.2210 and blades 1.5mm thick AL-7075 aerospace grade aluminium. Those screws in the picture has been replaced to 10.9. grade screws. Secured by glueing and hammered small dents to other side. Did not want to weld them in the case of disassembly.

Please Freudie keep on going good work. This is highly recommended upgrade in my opinion. I cannot start making them more.

20200307_193958.jpg
 
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