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Custom airbox for pod filter, coming along nicely. 

 

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 Post subject: Custom airbox for pod filter, coming along nicely.
Posted: Sun Mar 02, 2008 12:41 am 
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Hi all,

Just wanted to let you know my latest project..

today I used an angle grinder and jigsaw to graft the top half of my airbox to the bottom section of a heavy duty boot mount battery box.

worked great, has huge internal volume, has 2 separate cold air inlets and doesn't appear to restrict the air flow at all as compared to the pod by itself. (its also just as loud intake noise with the box as without which is cool too.)

Anyway, Its in and working, when I've neatened it up abit, I'll take some photos and post them here.

The box has been moved toward the headlight a heap to get more volume, it picks up cold air from behind the indicator and the ED snorkel needed a slight mod to fit but works great, but you have to look pretty hard to notice it isn't factory.. and it works brilliantly, total cost has been less than 50 bucks not counting the pod filter itself.


rgds

Frank
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Posted: Sun Mar 02, 2008 5:33 am 
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So where are the pictures?

BenJ

 

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Posted: Sun Mar 02, 2008 6:56 pm 
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lol i was thinking the same thing..pics or its not happening!

 

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Posted: Sun Mar 02, 2008 7:40 pm 
Getting Side Ways
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Sigh...

fine, here are some photos as it is now.. keep in mind that I had no idea if it was going to work when I did it so I could have been a heap neater. (whole thing took about 1.3 hours.) Also, I've not finished sealing up the bottom of the box yet.

This first one shows how close it is to the headlight now. (and how far it is from the old mounting boltholes.)

Image

This second one shows the battery box base and where I grafted the lip of the old box to it so the lid would sit snug. still have to invest in some black silicon to make sure its airtight.



Image

There, proof I did what I said.. it will look perfect when I've finished, and provide no restriction to the air flow at all either. (and all of it cold)

thinking of cutting a 2.5 inch hole in the inner guard under the box and running some ducting though it and down behind the front bar, but not sure if it is really beneficial as it seems to feed plenty from the indicator access hole.. will see. (love that induction sound too. :-)

The cover comes off for access exactly the same way it used to (the 4 clips) and i cut the foam edge off the old filter to use as a gasket for the lid.. It has at least 4 times the internal volume the old one had. (and pod instead of panel obviously)

what do you think?

I had planned on fabricating one from checkerplate aluminium, but this one works perfectly, cost less than 70 bucks including the filter itself and looks almost factory. (or it will when I'm finished neatening my rough job)

Did all the cutting with a jigsaw and an anglegrinder. and like I said, the whole thing has about 1.5 hours in it thus far.

If people like it, maybe I'll photo document how I did it from end to end.

rgds

Frank
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Posted: Sun Mar 02, 2008 8:14 pm 
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Hey man that looks ok. Can you still get to the light or do you have to remove the box? Nice work.

 

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Posted: Sun Mar 02, 2008 8:42 pm 
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That looks good.

Interesting concept. I like it.

BenJ

 

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Posted: Sun Mar 02, 2008 10:23 pm 
Getting Side Ways
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You really have to pull the box out to get to the light, but considering it has only 2 bolts and the snorkel. (and the intake pipe of course) you can have the whole thing out in about a minute. besides how often do you need to replace a globe? dunno about you, but for me it isn't enough to worry about an extra minutes work to do it. :-)

most important consideration was having enough volume and cold intakes that the presure drop was insignificant and I think I've achieved that because it feels snappier off the line now.

rgds

Frank
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Posted: Mon Mar 03, 2008 12:30 pm 
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don't forget to leave a small drain hole in the bottom.

looks neat

 

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Posted: Mon Mar 03, 2008 12:34 pm 
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good idea, hadn't thougth about that..
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Posted: Wed Mar 05, 2008 12:43 am 
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will finish this in two weeks and take photos in and out.

need do add some ducting and seal it up abit.

3 days in and I am really happy with the results thus far.
have new mags to put on so thats gonna occupy me this weekend. (need tyres and stuff)
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Posted: Wed Mar 05, 2008 12:54 am 
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nice work dude

never thought of using a battery box

any chance of gettign the box model etc for other members who may wish to try this?

 

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Posted: Wed Mar 05, 2008 1:38 am 
Getting Side Ways
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Ride: BA XR6T (mix of BA, BF and FG)

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WA, Australia

love to but I haven't a clue what it is..

I was walking around for hours looking for inspiration to hit me... walked past my boat and looked over the side.. first thing I saw was the battery box and a light bulb lit up.. couldn't believe my luck that it was almost exactly the right width and height.

I will post the measurements of it though, but it was a just a no name battery box built of a falcon sized battery.
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