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Discussion Starter · #1 ·
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.
 

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Discussion Starter · #3 ·
I see 30 pics, not counting the two avatars.

how many are you seeing?
 

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I see them now. WOW that looks good. I am going to do that to mine. I think I will use plexi glass to cover the opening. Then paint them.
 

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EXCELLENT JOB AND WRITE UP:bigthumbsup::bigthumbsup::bow:

I thought you'd be using some of that carbon fiber that you're hoarding:joke:
 

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Discussion Starter · #6 ·
EXCELLENT JOB AND WRITE UP:bigthumbsup::bigthumbsup::bow:

I thought you'd be using some of that carbon fiber that you're hoarding:joke:
Thank you.

This how-to was a duplication on a prior mod, before the CF.

I am holding on to them right now, waiting for a scrap that will cover the mounting plate.

I did not think that needed to be part of the how to, but we may see a picture of it soon;)
 

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i will definately post pics when i get them mounted :drool: cant wait:D excellant write up:bigthumbsup:
 

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Great job!! Very inspirational and it looks fantastic!

I wish I had tools to play around with to do cool stuff like that :edit::edit:
 

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It kills me how 2 or more people can come up with the same idea.I was drawing this out la couple of months back and never got around to it. Great minds think a like.:bigthumbsup: Great write up! :congrats:

One thing I would do differently is to run a long bolt or piece of all thread through the box. I have made a few different intakes and used resin glues like fiberglass or epoxy and it tends to want to crack after awhile.At least with the bolt going through it it's a safety back up for you.Hate to see you lose a hypercharger on the road some where.

Again Kudos!!! Looks Great!!!
 

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Discussion Starter · #12 ·
One thing I would do differently is to run a long bolt or piece of all thread through the box. I have made a few different intakes and used resin glues like fiberglass or epoxy and it tends to want to crack after awhile.At least with the bolt going through it it's a safety back up for you.Hate to see you lose a hypercharger on the road some where.

Again Kudos!!! Looks Great!!!
I am not too worried about that on this one in particular as I am still planning a carbon fiber wrap.

Even without it, plastic epoxies melt the plastic together as much as they act like glue.

If that is a concern though, you could always leave one or two of the stock filter mounting bolts.

I expect people to take this mod and mod it, so go crazy.

Look, even my first reply thinks he will do it in Plexiglas.

Mod on!
 

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Beautiful job bro.:bigthumbsup:.... This is the exact way i originally mounted my Air filter housings back in 08 but i went with an aluminum front plate and added a "safety" bolt straight through the back of the box just incase the glue ever gave up and the front plate tried to seperate... I since switched to the aluminum adapters.......

I will say though, yours are alot cleaner than mine were... Again Very nice job :bigthumbsup::bigthumbsup:
 

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i did this mod on my 90 after seeing a few of the 9's doin it because there are no after market intakes for the 90 yet.




 

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Discussion Starter · #17 ·
Thank you all.

I do want to be clear that I do not see this mod so much as a hyper charger mod as it is converting a stock air box to a universal mount to accept any custom intake you like. That is the part I want credit for. People have done the chargers before. The mount is the part from my head.

Here is a thought: do the plate in aluminum roof flashing and polish it if you are using and intake that will have it showing.

P.S.

If you like this one, wait until you see my "trunk" mod.

I will need a donor bike for the how-to on that. I found the how-to so much easier when it was the second time around on the build and I already knew where I was going rather then figuring it out as I went.
 

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WOW!
Excellent explanation & write-up!
I just purchased the adapter plates & bowls from Thunder Mfg. ( Tornados ) or I would do this one for sure. It looks a ton cleaner than using those big bulky metal plates over the stock/OEM sized bowls...:bigthumbsup:
This sort of stuff is what makes this web-site sooooo great!:super:
 

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Discussion Starter · #19 ·
One thing I would do differently is to run a long bolt or piece of all thread through the box. I have made a few different intakes and used resin glues like fiberglass or epoxy and it tends to want to crack after awhile.At least with the bolt going through it it's a safety back up for you.Hate to see you lose a hypercharger on the road some where.
So, I was thinking about this.

The box is only about 3" thick, so it would not be a big deal to just run a drill bit through one of the mounting holes on the plate, straight out the back side, so you could use a long bolt. As long as you sealed up the back side, it couldn't hurt anything.
 

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Know thats Custom !!!!!!!!!!

Man you did one hell of a job putting that toghter, some of you guys are funking creative with the mods... IM like Blade " You make the weapons and Ill use em" :bigthumbsup:
 
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