Wider Holley Intake

[Munchy]

Hi all, this wasn't going to be a "how to" but by the time I uploaded all the photos to explain what I had done it kinda ended up that way.

I have always liked the Holley mod because I thought it gave the best bang for your buck and I liked the clean look. But I see many had problems with fitting the clips on and I liked the use of perspex (I think plexiglass to you guys) used in early mods to keep some heat away.
So I went a step further and used 2 layers of perspex to allow room for the clips and this tidied things up while spacing the Holley units further out.

But this is a lot of work and took quite some time.
All the cutting was done with a jigsaw and then filed and sanded.

Anyone that has had the stock cleaners apart will know that the lip the stock filter sits against is raised
http://image1.frappr.com/pix1/i/20080713/8/d/0/8d0ab6a190f801524530cf10b22b41eb0_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/Razed.jpg

So the first layer is cut oversized around the old air filter area
http://image1.frappr.com/pix1/i/20080713/8/2/8/828ab5255e4ca9c7f47eb64cd4b6cde90_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/lowersheet.jpg

The shaped hole in the second layer is cut closer to the shape of the plastic.
Notice all the raised lumps around the screw holes are all different heights and I had to drill all the holes to suit.
I tried to make them all have a small amount of clearance when assembled and I used a spade drill the same as you would use on wood so the bottom of the holes are sort of flat.
Of the larger holes the two lower and the centre top are drilled about 2mm into the second layer.
http://image1.frappr.com/pix1/i/20080713/c/c/1/cc15a32c660fa4da7c19b5d6b5b55a610_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/Sealgroove.jpg

This is both layers ready to glue (just 1 side) I used Araldite and sanded the surface to be glued.
Notice the second layer with the extra cut off the top and bottom for the clips, and the odd shaped hole at the bottom is serves no purpose.
http://image1.frappr.com/pix1/i/20080713/f/3/2/f32a3fac442eb4ff415028ad97bee0bd0_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/Holley1.jpg

I got the back plates blank so I could cut them as I wanted.
http://image1.frappr.com/pix1/i/20080713/3/6/3/363a8bb2d292555977d1104ded13af7f0_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/Holley2.jpg

I Used Silicon to make a seal surface and left it flat with the perspex so it will compress like rubber when dry.
I also used silicon to seal the holley back plate to the perspex and silicon on bolts and screws on assembly.
http://image1.frappr.com/pix1/i/20080713/0/3/a/03a8658d71ea2e7d530277a8e862f6720_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/seal.jpg

This is the adaptor on the bike ready to have the filter element installed.
I used the original screws thru the holes that once held the original elements in place and 5mm stainless bolts for the rest.
http://image1.frappr.com/pix1/i/20080713/7/1/a/71a2f2dfd6f16a5acb855332cd1bb8780_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/Assem4.jpg

This is off the bike with the holley attached, I painted the edge matt black to suit the plastic.
http://image1.frappr.com/pix1/i/20080713/3/1/f/31f4d118ce3da5dbb5c5505259244ec90_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/Assem1.jpg

This is the end result
http://image1.frappr.com/pix1/i/20080713/6/2/8/6288d37d246df3a94f0ac3cfb981144c0_large.jpghttp://i819.photobucket.com/albums/zz112/craignkathy/Holley%20Air%20Intakes/Assem3.jpg
http://image1.frappr.com/pix1/i/20080713/a/2/7/a27dbb5113c7f1118808a264058485880_large.jpg
http://image1.frappr.com/pix1/i/20080713/e/1/8/e18e31a2b6ccf233b7b25b5d91628f2a0_large.jpg
http://image1.frappr.com/pix1/i/20080713/a/8/1/a8187ebd5162926ba2f947f12ade793b0_large.jpg
http://image1.frappr.com/pix1/i/20080713/8/2/3/8237015636171adec4bae475531725790_large.jpg

As I said before this is a lot of work but I think the result is good and tidy :P

I have a few more mods on the go so I will keep you posted.

Cheers
Munchy

[WAYNE109]

Very neatly done! :bigthumbsup:

[Dark Shadow]

Great step by step. That was an excellent job. Very clear and easy to follow. :bigthumbsup:
There are a lot of Holley intake users that will love this thread.

[tonymontanna1983]

Great job Munchy. Maybe the best looking Holley-mod I've seen .

[Hamdaddy]

Very neat, clean and nice. :bigthumbsup:

[M109R-N-KY]

Thanks for the How to. :bigthumbsup: I liked it so much I made a pdf file and saved it for later.( mod list just keeps growing)

[BIGIRISH109]

Looks nice. Alot of work and time for something most won't even notice but, well worth the effort!

[Bullie]

if you get bored and want to make another set of those.......I'm buying!! Sent PM

[atakdog10]

That's the fix we need on these filters. I would buy a set also, just tell me your price.

[rynosback]

Nice job. It looks great. :bigthumbsup:

[aceventura]

Great step by step. That was an excellent job. Very clear and easy to follow. :bigthumbsup:
There are a lot of Holley intake users that will love this thread.


VERY NICE write up :agree: :congrats: :yourock: :bad2thebone: :a18: :2cool: :#1: :beer3: :beer2: :clap2: :clap2: :clap2:

[Giddyup109]

Sweeeeet! I have these and I just "forced" the wire behind the cover because it stuck out to far. This is a great idea to get a cleaner and more flush look for these intakes!

[Munchy]

if you get bored and want to make another set of those.......I'm buying!! Sent PM

That's the fix we need on these filters. I would buy a set also, just tell me your price.
Sorry guys but you may have noticed the state of my garage in the pics which is due to me being half way through renovating part of our house.
I had enough grief from the little lady when doing my own work on my bike (which aint finished yet either).
But I am more than happy to give anybody any tips or help online.

And thanks for the comments :D

Munchy

[HyperPete]

Is there any chance you can trace those spacers and post them as templates? That would be great...

[Munchy]

Is there any chance you can trace those spacers and post them as templates? That would be great...

Sorry not without tearing the units apart again but all I done when I made mine was make a cardboard template.

I marked thru the screw holes in the airbox first and cut holes to suit the raised portions on these then pressed around the old filter area with my thumb to mark it and cut this out oversized by a mm or two.
I finaly marked the outside with a pencil but I used the airbox to mark the outside of the plexiglass to finish off after I had glued both sheets together. But I did use the cardboard template to work out and mark where the retaining wire cut-outs go.
My template was pretty rough but the important thing is getting the holes in the right place then final fit up is after you drill the holes and mark off the airbox itself.

I had done 3 pairs before I was happy.

Hope this helps
Munchy

[Nebraska_Marine]

I got the back plates blank so I could cut them as I wanted.


How did you go about that? I'd love to do this mod exactly as you've done, but don't know where or how to get "blank" back plates. Thanks for the post!

[Munchy]

I used Ramflo filters which seem to be exactly like the Edelbrock.

I got mine at a local (New Zealand) supplier http://www.autopia.co.nz/ramflo.htm?sub_1_1=&menu_1=&

The US site is http://www.ramflo.5u.com/

I couldn’t find exactly what I wanted on either site so I sent Autopia an email and asked what the options were on backing plates and they said they could get blanks. The entire filter units cost me around NZ$100 each which is quite expensive for what they are but it was exactly what I wanted.

[wallyn591w]

what a great job very sweet :bigthumbsup:

[crayzj]

Have you heard any differance in the air intake sound or performance :dontknow:...Would buy a pair in a minute...looks awesome...Very neat and clean.:bigthumbsup: :clap2:

[rynosback]

I was looking for this post the other day. You did an awesome job again. :bigthumbsup:

[wallyn591w]

excellent:clap2:

[Munchy]

Have you heard any differance in the air intake sound or performance :dontknow:...Would buy a pair in a minute...looks awesome...Very neat and clean.:bigthumbsup: :clap2:
Thanks.
Definately yes to both.
There have been posts quoting 6 to 8HP gains and I would say thats fairly real.
There is a noticable increase in induction noise and I just can't get enough of it.

[Boogaone]

Thanks Munchy, I have wanted to go with a Holley air kit but have heard problems with fitting the standard kit and over the past few days have been thinking how I could make it better. Then, I found this thread.

Love your work :bow:

I'll be going this way definately.

[geosr1]

Thanks.
Definately yes to both.
There have been posts quoting 6 to 8HP gains and I would say thats fairly real.
There is a noticable increase in induction noise and I just can't get enough of it. i just finish my holey mod and i wish i would of seen this one this very good and i wish mine came out like that but hopefully it would work thanks for the step by step

[yahooskidoo]

Could you please post part #s for the filters and blank base plates.

[rynosback]

Could you please post part #s for the filters and blank base plates.

With the Holley airs you use no filters, just the foam as the filter that comes with it or a lot of people use the K&N filters.

If you are talking about the base plate on the left (metal part), it comes with the Holly airs.

http://image1.frappr.com/pix1/i/20080713/3/6/3/363a8bb2d292555977d1104ded13af7f0_large.jpg

[yahooskidoo]

Part # for blank base plate please, I'm sure it comes with a hole cut for a car carb.

[rynosback]

Part # for blank base plate please, I'm sure it comes with a hole cut for a car carb.

Here is a link to the Holley air kit (http://www.directlineparts.com/product.asp?pid=6954&str=290).

[Munchy]

Part # for blank base plate please, I'm sure it comes with a hole cut for a car carb.

Try this http://www.ramflo.5u.com/

I emailed the NZ supplier when I done mine and they sent me blanks back plates on request, I assume you can do the same.

[WickedRican]

Very clean! Awesome... :bigthumbsup:

[R.W.F/08r2]

Great job and picks I wish I would of got the solid back plates good idea I used K&N the crome showing through would look cool. Instead I had to black them out and bolted them together instead of the wire its alot more work for me to clean the filters and recharge them:bigthumbsup:

[rynosback]

I am working on a spin on this. ;)

[jglass4763]

I' eagerly waiting to see what you come up with.

John

:bigthumbsup:

[Syco]

Great Job Munchy......haven't decided on the Holley yet but this just might tip the scales. :bigthumbsup:

[rynosback]

I was think of making something like this with a built in lighting for the stock covers, Tony/Ducks mod and the Holley Mod. How many people would be interested in it?

[jglass4763]

Count me in!!!!

John

[EYELESS]

I was think of making something like this with a built in lighting for the stock covers, Tony/Ducks mod and the Holley Mod. How many people would be interested in it?

I was thinking something similar, if you're using plexiglass, you could mount a couple of LEDs in it and it the light would shine outward in all directions from behind the air cleaner as long as the edges are not painted:bigthumbsup:

[rynosback]

I have not ruled out LEDS but I was thinking of a neon light in there.:dontknow: I still have to take the time to make the templates and then figure out what is the best way to mount lighting in there. I will post pictures when I have it done.

[Munchy]

I was thinking something similar, if you're using plexiglass, you could mount a couple of LEDs in it and it the light would shine outward in all directions from behind the air cleaner as long as the edges are not painted:bigthumbsup:

:agree: I think that would be cool

[pynikal]

the link on DLP for the install on these is broken. does anyone know a good link??

[rynosback]

the link on DLP for the install on these is broken. does anyone know a good link??

The link for the install of the Holley Air? I think I have it somewhere if you can not find it.

[pynikal]

The link for the install of the Holley Air? I think I have it somewhere if you can not find it.

yeah for the holley air. on DLP it links here but the link is broken. i will search some more.

[rynosback]

yeah for the holley air. on DLP it links here but the link is broken. i will search some more.

I PMed you a link, I hope it works out for you.

[Rusty]

I am on the trail of the ever ellusive blank back plate. I found the place in New Zealand (I think) that actually has the blank back plate called out with a part number. Anyway I emailed them to see if I could get those and what the cost would be. In the meantime I also found out that Holly also sells the back plate seperatly but it is just the normal backplate that fits the 4 barrel carb, so I will call them and see if I can get one that has not been stamped with the holes and see what they say. At least it is a little progress. Hopefully. :drool:

[RonnieTheBull]

This would be sick...I maybe late or out of the loop as it appears to be a dated thread...but if anything is still in the works I would be interested as well :bigthumbsup::bigthumbsup::bigthumbsup::bigthumbsu p:


I was think of making something like this with a built in lighting for the stock covers, Tony/Ducks mod and the Holley Mod. How many people would be interested in it?

[rynosback]

This would be sick...I maybe late or out of the loop as it appears to be a dated thread...but if anything is still in the works I would be interested as well :bigthumbsup::bigthumbsup::bigthumbsup::bigthumbsu p:

I have had to put it on hold for a little while, but I have a template made for the stock covers and just need to find the time to start cutting them out. I'm still trying to get a trace of the backing plate for the Holley air so i can make them for those also.

[Pegasus]

This is quick and crude for now, but Iv've found an easier way.

Cut down the stock air cleaner cover as pictured. Transfer the hole pattern to the Holly back plate. (pic)(I'm using an edlebrock that's different, picture a flat plate) Put some silicone sealer between the modified cover and the Holly back plate and assemble (with longer screws) like you normally would with the air cleaner cover. If you want it to be a cold air only set up you have to block off the round inlet of the stock backing plate and remove the stock air filter. You can make some small holes and use sheet metal screws or drill out the plastic and the back plate a little larger, and use nuts and bolts.

[the Other Orange 9]

If someone comes up with the back plate or a template or dwg, I can cut these out on my CNC router table.

Dan

[Rusty]

If someone comes up with the back plate or a template or dwg, I can cut these out on my CNC router table.

Dan

I never was able to find a back plate for a reasonable cost. When ordering them out of Australia or where ever the blank back plates come from they want a fortune for them. It was close to $300.00 for two filters identical to the Edelbrock only with a non cutout backplate. It was freakin rediculous. For what we pay $40.00 to $50.00 for here in the states and this was supposidly him given me a good deal because he was supposdly real close to the owner of Lynx Filters. Yeah right.

I wonder if we could find someone to stamp these back covers out for us at a reasonable cost?

I have a buddy working on the plexiglas templates but still would like to find a way to have the backplate of the filter itself solid so we can cut them out like in the original post here.

I think Pegasus idea is an interesting one as well.

[m109pilot]

Hey Munchy I just had to get on here and say thank you for posting this!!

I recieved my Holley kits from DLP and to be honest was completely disapointed! I thought I had made a bad choise here and was a bit pissed at myself for not doing a little more research before hand.

However that said I came across your post yesturday and well today the paint and silicone are dry and I am ready to install them. The spacers turned out great and like yours look factory.

Alot of work went into it mind you and it cost me approx $100 CND for the plexi, glue, silicone and paint. The 6 hours work was well worth it in the end.

Thanks again Munchy!!! :bigthumbsup:

Pilot.

[Pegasus]

This is quick and crude for now, but Iv've found an easier way.

Cut down the stock air cleaner cover as pictured. Transfer the hole pattern to the Holly back plate. (pic)(I'm using an edlebrock that's different, picture a flat plate) Put some silicone sealer between the modified cover and the Holly back plate and assemble (with longer screws) like you normally would with the air cleaner cover. If you want it to be a cold air only set up you have to block off the round inlet of the stock backing plate and remove the stock air filter. You can make some small holes and use sheet metal screws or drill out the plastic and the back plate a little larger, and use nuts and bolts.

I finally finished my holly/edlebrock intake mod.

I cut down some stock air covers (damaged ones I bought cheap) to make my own mounting rings as shone in the original post. I made the right side 3/4" wide and the left 1-1/4' wide. Now they stick out the same distance from the tank.
I cut little grooves for the spring wires so that the mounting ring fits over them. It means you have to take the air boxes off to clean the filters (just like stock), but there's no way they can come off while riding either. (see close up pic). I ran a bead of silicone on the mating edge and let it set up. Then I used longer thiner sheet metal screws to go all the way through the mounting ring and into the air cleaner back plate. I had to cut down the inlet flange that would normally mate up to a 4 barrel carb, as I bought mine from Autozone, and straightened out the remaining bend to make it flat with the rest of the back plate. I offset the mounting so that the filters would be more forward. This covered one of the vent holes so I only had to plug one.
I removed the stock filters and with the way I sandwiched it all together I didn't need to make spacers to fill in on the mounting posts that the filters mated to.
I just used some silicone to plug the little bottom vent in the stock box.

[Munchy]

Hey Pegasus, very tidy :bigthumbsup:

And m109pilot, you are welcome, I think it was well worth the effort too.

[Munchy]

Hey Guys,

Has anyone made a pdf or similar of my original post. Frapr seems to have gone along with all my pix. I have the photos along with a heap of others but I am not sure which ones I put on the post.
If I know which pix to repost I will load the photos onto another server.

Cheers
Munchy

[rynosback]

Hey Guys,

Has anyone made a pdf or similar of my original post. Frapr seems to have gone along with all my pix. I have the photos along with a heap of others but I am not sure which ones I put on the post.
If I know which pix to repost I will load the photos onto another server.

Cheers
Munchy

:dontknow: Just post what you think will best show it off. I have a wood template made, but i have not started cutting the plastic/lexan.

[cbxer55]

I've been running Edelbrocks since sometime in 06. But I did them the real simple way. I took the Edelborck back plates and tossed them. Fit the mesh assembly with the filter installed over the stock back plates, drill four holes at what would be approximately 90 degrees, stick a self-tapping screw through the Edelbrock mesh and filter into the stock back plate.

I also utilize the thingamabob, whatchamacallit, dohickie that Edelbrock supplies to keep the filter from collapsing against the intake hole.:D

Good to go. Its worked for me for dang near four years. Still makes that evil intake hiss that I prefer over a loud exhaust.:bigthumbsup:

[Remy]

:dontknow: Just post what you think will best show it off. I have a wood template made, but i have not started cutting the plastic/lexan.

Is there anyway you could make a copy of the wood template you made? I could cut the plexiglass myself if I had a good template.

[Munchy]

Is there anyway you could make a copy of the wood template you made? I could cut the plexiglass myself if I had a good template.

When I done mine I took one of the air pods off and marked thru the holes, once you have made the recesses with a spade drill so the pod will sit flat, the outside and the air intake hole can be easily marked.

[Scorp]

I know this is an old post but, I found a part number for the blank base plates (RF1000BP) but i can't find anyone in the states that can get it for me. This is the way i'm wanting to do the filters on my bike. Great Job!!!

[Rusty]

I know this is an old post but, I found a part number for the blank base plates (RF1000BP) but i can't find anyone in the states that can get it for me. This is the way i'm wanting to do the filters on my bike. Great Job!!!

Nobody in the states has them, and even if you do order them from overseas they charge you an outrageous amount each. It's freakin rediculous. I even tried calling Holly and Edlebrock to see if I could get some before they were stamped. No go.

[Scorp]

Ok thanks for the update. I tried Holley with a no go. Haven't heard anything back yet from Edlebrock.

[M1K]

Has anyone tried running the K&N's as well as the foam? Why I ask is cause the Edelbrock foam doesn't seal around the edges very well. I have both in place but bike is still in pieces therefore have not ridden it yet. Will this still provide enough air... don't want to lose any performance.

[Munchy]

Try repositioning the foam around the cage to make sure the foam touches all round, it only needs to sit against the back plate and the oil should help the seal.
Not sure about the K&N's but with the foam element you need to keep them well oiled with filter oil otherwise they will pass fine dust.
I clean mine every couple of months and only once have I found any signs of dust on the inside of the filter.

[rynosback]

Has anyone tried running the K&N's as well as the foam? Why I ask is cause the Edelbrock foam doesn't seal around the edges very well. I have both in place but bike is still in pieces therefore have not ridden it yet. Will this still provide enough air... don't want to lose any performance.

Yes a lot of people have run K&N's along with the Holly Mod.

[M1K]

Ya I think if I was only going to run the foam I would coat the air intake runners with vaseline or grease. This will give you an indication as to how good your filter is and also provide a bit more filtering. Very common practice in the motorcross scene.

[bigbody67]

I've been running Edelbrocks since sometime in 06. But I did them the real simple way. I took the Edelborck back plates and tossed them. Fit the mesh assembly with the filter installed over the stock back plates, drill four holes at what would be approximately 90 degrees, stick a self-tapping screw through the Edelbrock mesh and filter into the stock back plate.

I also utilize the thingamabob, whatchamacallit, dohickie that Edelbrock supplies to keep the filter from collapsing against the intake hole.:D

Good to go. Its worked for me for dang near four years. Still makes that evil intake hiss that I prefer over a loud exhaust.:bigthumbsup:



Hey is there any way you could supply some pictures of this way? I dont have all of the tools to do the plexiglass set up. This sounds like a pretty easy way to do it. Any help would be awesome!

[Dragonback]

Not to mention that you can find the Plexiglass in many different colors.. which can accent the bike.. I first made it in clear.. But have since gotten shinny Black.. but now mayb looking to put spike air kit.. im so confused!! :dontknow:???:dontknow: :-\

[scalemaster]

I have a "Q" I just order a set of Holley ,so r this the same as the ones for the cars or r they diff .

[Latinrascal]

The same although they come in 2 different sizes where the holly backplate would mount to the intake. Either one will work since you will be cutting it out anyway.

[Boogs109]

I have a "Q" I just order a set of Holley ,so r this the same as the ones for the cars or r they diff .

Email/phone the dealer and ask for blank backing plates (they can supply blanks). This way you can cut your own hole in it any shape you want.

Boogs

[scalemaster]

Thxs guys for that info .

[Rusty]

Email/phone the dealer and ask for blank backing plates (they can supply blanks). This way you can cut your own hole in it any shape you want.

Boogs
I tried this and no deal. I tried Holly and Edelbrock and neither one really wanted to talk. Maybe you have a better in than I did. If so can you explain how you did it?

[Latinrascal]

I tried this and no deal. I tried Holly and Edelbrock and neither one really wanted to talk. Maybe you have a better in than I did. If so can you explain how you did it?

There really is no need for a blank backplate other then it makes it a tad bit easier to lay your pattern out. Your gonna cut away most of the material where the hole is already stamped in the self kits and with that big hole already there its just that much less cutting you will have to do!

[Rusty]

There really is no need for a blank backplate other then it makes it a tad bit easier to lay your pattern out. Your gonna cut away most of the material where the hole is already stamped in the self kits and with that big hole already there its just that much less cutting you will have to do!
I certainly agree, I just was trying to let others know it could be very difficult to find blank back panels.

[Scorp]

I certainly agree, I just was trying to let others know it could be very difficult to find blank back panels.

You can't get them here in the states. You can have them shipped into the states but your going to pay almost 100 bucks each.