MOD YOUR STOCK AIR BOX AND FILTERS TO MAKE MOUNTS FOR CUSTOM INTAKES
This is my first effort at a full fledged “How-To”, so give me some feedback on not just the mod, but the How-To itself.
Well, I liked the look of hyperchargers, but thought it made no sense to spend $750 for the kits that are out there.
I found a similar looking intake, but that left me in need of a way to mount them to my bike. I took apart my stock intake and came up with what follows.
When I did it, I was not thinking it was a big deal or that anyone else may be interested in it, and I was figuring out the process as I went, so I have no pictures.
I posted my result in a couple of places an several people asked for a How-To on the mod, but with no pictures, it would have been a little tough.
JMAKAMN was one of the inquiring members. I was going to walk him through it and have him do the How-To, but figured it would work out better if he just sent me his parts and I did the mod so I could take pictures this time around. So, I am not sure where JMAKAMN got the air boxes he sent me, but you might want to let the person know that their bike was puking a little oil.
Thanks to BigpapaM109 for the stock air filters.
Let’s get down to it then:
I trust you can get to this point, stock air boxes and filters removed:
Remove the drain lines so they do not get damaged, you will need them later:
Note that the click in tab on the air box on the left, which is the right side air box, is broken off. I just do not want to get blamed for this later.
Next: Take a Dremel, saw or whatever tool you like and cut the fiber filters off of their mounting plates:
Next: Trim the filters’ mounting plates so you keep the seal:
Next: Be sure to remove this high spot:
Next: Now do the other one:
Next: Grab something in a black heavy plastic. I have tons of Dewalt boxes around, so that was what I used as my donor:
Next: Cut out a section:
Next: Use some course sandpaper and add a consistent texture to the filter plates and the donor cut out:
Next: Use a good glue of your liking and mount the filter plates to the donor section:
Clamp this up and allow to dry:
Next: Move on to the air boxes We want to keep the sections in “color” (even thought the color is black) and remove the Black & White sections:
Using your dremel, or other cutting tool, cut away the portions of the stock air box outside of the filtered air chamber. Make sure to leave the mounting tab so you have a place to bolt back onto the bike:
Next: Do the other one:
Next: Get the sander back out and clean these up and put a good texture on the entire outside:
Next: If you used a 30 minute plastic epoxy, your plates should be done by now. Unclamp and sand the edges and surface to get a matching texture:
Next: Trace the hole and bolt pattern of your chosen intake:
Next: Use your tracing to transfer matching holes onto your mounting plate:
Next: Glue your mounting plates onto the boxes and clamp them together. You may as well reattach the drain lines here as well:
Let the glue dry and you are done:
Mount them on your bike and use appropriate bolts to secure the intake through the mounting holes.
It should look like this:
Hopefully, JMAKAMN will post some pictures when he get these mounted up to his bike.
I hope someone finds this helpful.