Custom Air box, updated

From cardboard patterns to layout on aluminium.
Haven't had much time to work on this due to work. So today I started layout on aluminum (aka: kick plate for doors) 10" x 34" 2 sheets. Enough for 1 box.
Drain hole, pcv valve will be retained.

 

Save some material for bracing. That thickness of aluminum isn't going to be as rigid as ABS. There might be some movement caused by the intake pulsation, and that could lead to fractures over time.

Cardboard Aided Design is the best.

 

Good on ya for this!
Are you welding it?

All my CAD is done this way too

 

Yes, I am welding it. Ill have leftover material if it needs structural stiffening. If it was bigger I would install internal ribs. With a 4" inlet and very little flow restriction, pulsation shouldn't be that bad. If anything the stiffening can be added to the outside. Granted, inside would probably add a bit of turbulence to the flow.
The heat from welding may cause draw or warping, so
stiffening wouldn't hurt.

Cardboard is the best for mock up. Cheaper than any other material.
3d scanner & printer would be far better but good ole custom fabrication & welding is far less costly.
Time to go buy a jigsaw.
Thanks for the encouragement. I figured doing this it should have its own build post.

 

I like where this is going...

 

front & back are cut out.
Taking the carb side to work tomorrow so I can use a hole saw on the outlets. Radius is too tight for a jigsaw blade. Then clean up edges with a dremel sander
Looking at this massive 4" maf adapter. Im hoping I dont have to relocate the battey or add a 90° to kick the filter outside of the frame. 4" is what was ordered but really could use a 3"

 

Out of interest what's the main motivation for this project?

 

Not using pods.
Ease of air box removal.
Which would make carb removal far easier.
Shiney aluminum air box looks far better than the black plastic factory air box.
Attempt to achieve better airflow than stock box.
Rejetting would be a bit faster.
Because I can fabricate items like this with minimal effort & low cost for materials.

 

Cool.

 

That is a sweet project, makes me wish I still had a tig welder.

 

I have several hundred. I propose, contract and manage large boiler shutdowns.
The boilermaker union has the best TIG welders of all the trades.
A pipefitter is ok if you can rotate the piece for him, LOL.

I'll soon see how many PF's we have here.

 

Idk, those nuke plant pipe welders have to be the best.
I can weld almost all processes. Not the best but definitely not the worst. I can get by for the most part.

 

W

Wire feeders can be converted for tig useage.
See youtube

 

I currently have a millermatic 212 mig, wanted a dynasty 200dx or similar for years. Can't justify it financially though, unless I figure out some way to make money with it. But I suppose the airbox could be welded with just a spoolgun with the 212. welds might not look as good though.

 

I agree. You really have to know how to run a spool gun to get high quality tig like welds. I did it for a while working with austal. Its not easy. Lots of patience, lots of controlled travel speed, proper spool feed speed as well.

 

Airbox update:
Work has been working me and not allowing time for my bikes. Plus hunting eason is just around the corner. Anyhow, I decided to go with 1/8" plate on the carb side. Reason being; the boots would not have made a decent seal on the 1/16" material. Its possible they would have but, the boots have a 1/8" groove. So why not. Even with the material change, I'm barely under 100.00 in total cost. All thats left is to trim, scuff & dull up the weld areas. Tack & test fit for clearance with single filter. Building 2 at the same time. 1 will use a 4" cone filter, the other will use a 3".
I've also hacked up a stock air box to use a single 3" cone filter. Adding more pics as I go along.
Welding will be done at work. No gas for aluminum at home yet.

 

The stock box hack is complete with the spectre 1413 3" maf adapter and k&n filter. Total cost on this is right at $40.00 this one is for the 650 just to get it running. If work allows, ill tack weld up 1 of the boxes this week.

 

Curious how this turned out?

 

Me too be interesting to see it finished.