custom made airbox

[Pipeless416]

for a fabrication class i took as an elective, we have to have a final project. i decided to make an aluminum airbox that would relocate my battery, but then i started TIG welding and that changed that idea pretty quickly :o . anyway, i just said screw the weight, and ended up making it out of steel. all the sides were cut with huge pneumatic shears.. the name escapes me right now.. and the airboot hole was cut using a cnc plasma cutter. the rest was MIG welded together, on the wrong setting haha. anyway, all thats left to do is weld some brackets on and have it powdercoated. :D i made it so the length is correct for a shorter 450r carburetor. this also opened it up a little bit on the inside. oh, the diamond plate battery bracket was made in 30 seconds lol. heres the most recent pics.

[Pipeless416]

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[Pipeless416]

..

[97WarriorRider]

acutally looks pretty good..How much does it really weigh though..I wouldnt be to concerned of the weight

[Pipeless416]

its probably 10 or 15 lbs. i'll just go on a diet lol. if i raced i'd be concerned, but for what i do, who cares?

[Pipeless416]

i'll either be going with a candy red, gloss black, or a chrome powdercoat. any suggestions?

[BrianD]

How are you able to remove the battery with the diamond plate strap? Is that plate bolted to the box?

[mcwilly]

Looks good. I'd go with a gloss black.

[97WarriorRider]

Originally posted by Pipeless416
its probably 10 or 15 lbs. i'll just go on a diet lol. if i raced i'd be concerned, but for what i do, who cares?

Is that with or w/o the battery?

[Pipeless416]

Originally posted by BrianD
How are you able to remove the battery with the diamond plate strap? Is that plate bolted to the box?

im gonna drill then tap a hole into the caliper cutaway and the screw will just go in from the outside. the top will just have a bolt and nut.

[Pipeless416]

Originally posted by 97WarriorRider
Is that with or w/o the battery?

i'd guess about 15 how it is in the pictures.. boot, battery, bracket, filter, and box.

[Ruby Soho]

lookin great

does this also solve the problem of having to move the airbox up for the 450r carb?

[97WarriorRider]

that doesnt sound to bad..considering how much the battery weighs

[Pipeless416]

Originally posted by Ruby Soho
lookin great

does this also solve the problem of having to move the airbox up for the 450r carb?

yes sir it does. i the materials are all free too :) . i'll be cutting out an aluminum switch and neutral light holder too, since i put the quadtech hood on.

[Brauap]

Originally posted by Pipeless416
i'll either be going with a candy red, gloss black, or a chrome powdercoat. any suggestions?

Looks real nice! Funny I am having my dad's friend make me one aswell out of aluminum. But I am not sure about the measurements. I want the battery inside, but I want it yo be easy to take my K&N in and out. How you have made yours, would it fit the stock 400EX carb? Also could you please just give me a little measurement on how deep it is at its deepest part.

Thank You and it looks good, I'd go w/ gloss black.

[Pipeless416]

Originally posted by Brauap
Looks real nice! Funny I am having my dad's friend make me one aswell out of aluminum. But I am not sure about the measurements. I want the battery inside, but I want it yo be easy to take my K&N in and out. How you have made yours, would it fit the stock 400EX carb? Also could you please just give me a little measurement on how deep it is at its deepest part.

Thank You and it looks good, I'd go w/ gloss black.

i actually left my solidworks drawings in the shop, but for some reason i think i made it 6.75 inches deep. at least thats what comes to mind.. i'll check on monday. i don't think the exact dimensions i used will work with a 400ex carb, but i suppose the airboot could just be squished a little bit, afterall, the difference isnt huge. i might just make a slotted bracket on the back so if for some reason i ever decide to change back to a 400 carb, (if i ever go insane) i can just loosen the bolt and slide it back.

[tar]

Good idea with making it longer for the 450r carb. The way you were explaining it I thought it would look bad but it doesn't lol. I think you should pc the airbox CANDY RED it would look sick on your ex.

[400exBRAAP]

Originally posted by tar
Good idea with making it longer for the 450r carb. The way you were explaining it I thought it would look bad but it doesn't lol. I think you should pc the airbox CANDY RED it would look sick on your ex.


i agree, red kinda hidden in the background sorta would look awesome

[1trik88]

looks pretty similar to the one i made at work...

http://img141.imageshack.us/img141/8069/pic0752oi4.jpg (http://imageshack.us)
http://img352.imageshack.us/img352/9918/pic0753xo2.jpg (http://imageshack.us)
http://img404.imageshack.us/img404/456/pic0765fb5.jpg (http://imageshack.us)

good work with your box

[Pipeless416]

thanks for the compliments everybody. i cant wait to get my brackets installed on monday, and brauap- i'll get you some of the basic dimensions that i have so you can get started. anybody wanna photoshop the box gloss black or candy red..? :D

[Brauap]

Originally posted by Pipeless416
thanks for the compliments everybody. i cant wait to get my brackets installed on monday, and brauap- i'll get you some of the basic dimensions that i have so you can get started. anybody wanna photoshop the box gloss black or candy red..? :D

I'll attempt it. But I suck, and its not photoshop. But it will give you an idea.

Here is the org.
http://i197.photobucket.com/albums/aa283/braaup/CustomAirbox.jpg

Here is black.
http://i197.photobucket.com/albums/aa283/braaup/CustomAirbox-Black.jpg

And here is red.
http://i197.photobucket.com/albums/aa283/braaup/CustomAirboxRed.jpg

[Pipeless416]

thanks brauap! better than i can do since i dont have photoshop anymore lol. i think i'm gonna stick with gloss black because i don't know how well the candy red will flow.. and i know i said i'd get the dimensions, but i completely forgot! i can tell you that the hole for the airboot is 3.5 inches diamter, the entire box without the side brackets is 7.125 inches, and the angled part for the caliper is 3 inches tall, and 5 inches wide. the width looking at that part from the back is 3.4 inches. sorry i couldn't be of more help. i got the battery bracket situation figured out. i am using a set screw to hold the bottom part.. its pretty perfect for its application.. i'll get more pics of it soon! ;)

[Pipeless416]

alright i got some new pictures of the brackets i made, and the set screw i was talking about for the battery bracket. the box is off being sand blasted and powder coated gloss black, and i'll get some pictures of it when its complete.

[Pipeless416]

rear bracket

[Pipeless416]

left front bracket

[Pipeless416]

inside again while empty

[Pipeless416]

this is the tapped hole for the set screw. i used an allen head screw, and when it goes in, it catches the hole thats in the bottom of the mounting bracket, preventing it from moving.

[Pipeless416]

heres the set screw in place. and thats all for now! i'll get pictures of it pc'ed and installed on my quad as soon as i can.

[STUNTIN400EX]

LOOKS GOOD HOPE YOU GET A AN A+ FOR YOUR FINAL. DON'T WORRY ABOUT THE WRONG MIG SETTING ONCE ITS PAINTED AND BOLTED IN YOU SHOULD BE OK. JUST SLOW YOUR WIRE SPEED. WHAT MATERIAL DID YOU MAKE IT OUT OF .060, .090. NE WAYS GREAT JOB ON YOUR MOD!!!!:D

[Pipeless416]

Originally posted by STUNTIN400EX
LOOKS GOOD HOPE YOU GET A AN A+ FOR YOUR FINAL. DON'T WORRY ABOUT THE WRONG MIG SETTING ONCE ITS PAINTED AND BOLTED IN YOU SHOULD BE OK. JUST SLOW YOUR WIRE SPEED. WHAT MATERIAL DID YOU MAKE IT OUT OF .060, .090. NE WAYS GREAT JOB ON YOUR MOD!!!!:D

yea, i did have the wire feed way up, because i decided to go over the old welds, so i was basically just gobbing it on... and then forgot to turn it back down when i put the brackets on :devil: . the entire thing was made out of .090. thanks for the compliments.

[250x_kyle]

looks good. haha tigs not something you can learn over night. i learned that once. once you learn how to you can make just about anything out of aluminum or thin steel.

[Pipeless416]

since im waiting for my box to be powdercoated i thought id throw in my half hour project from today.. since i put a quadtech hood on, my ignition and neutral light have just been ziptied on. i made this little aluminum bracket to mount to the bar clamps.. its not completely done, as i need to make the bolt holes bigger, cut the notch for the ignition and its gonna be polished.. but its a product of sheer boredom. :)

[Ruby Soho]

wow looks awesome!

i love custom parts, good job

[Brauap]

Originally posted by Pipeless416
since im waiting for my box to be powdercoated i thought id throw in my half hour project from today.. since i put a quadtech hood on, my ignition and neutral light have just been ziptied on. i made this little aluminum bracket to mount to the bar clamps.. its not completely done, as i need to make the bolt holes bigger, cut the notch for the ignition and its gonna be polished.. but its a product of sheer boredom. :)

Make me one!! lol


You are real crafty! You should make a line of stuff and start off selling it on here and on eBay, then make your way from there, just like the Tinners.

Hey, maybe you can make some air scoops, or maybe sell the aluminum airboxes, or those nuteral/key switch holders. I think you could really make some money, you know?

[Pipeless416]

Originally posted by Brauap
Make me one!! lol


You are real crafty! You should make a line of stuff and start off selling it on here and on eBay, then make your way from there, just like the Tinners.

Hey, maybe you can make some air scoops, or maybe sell the aluminum airboxes, or those nuteral/key switch holders. I think you could really make some money, you know?

thanks Ruby Soho, and brauap, i'll only have access to the production lab for the rest of the semester because im a construction management major lol. although technically as long as im a student here i can work in there.. im gonna make a new set of scoops for mine soon and a new spacer for my brothers w/b e series. stay tuned!

[Brauap]

Oh, that sucks. Well, what do you mean a spacer? Also, while your there, make one of these I just thought of!

http://i197.photobucket.com/albums/aa283/braaup/OilCoolerEngineAirScoop.jpg

Man, I am a real need of some scoops. ;) ;) Seriously. lol

[Pipeless416]

e series pipes come with an inch and 3/4 spacer for the upper mount that pushes it away from the subframe. if you look in quicksvtech's (i think, not too sure on his name) thread, you'll see what im talking about.

[Pipeless416]

well since i already have a thread with random stuff in it, i'll keep posting in here. i finished the mounting spacer for my brothers w/b e series today. here it is..it needs to be polished too.

[Pipeless416]

sorry for the bad shots.. its not easy to take pictures of unless its mounted haha

[Pipeless416]

heres another shot of the dash mount i made.. i forgot the little notch for the ignition.. oh, and my box will be done tomorrow! :D

[Pipeless416]

hey brauap, your PM box is full but anyway, im not exactly sure if its even going to work yet lol. i have spring break this coming week and i'll be home, so i can polish it up and try it out. if all goes well and i get the ok from my professors, then i'll let you know. thanks for the interest.

[Brauap]

Huh:confused: I have 2 messages in my inbox. How could it be full?! Is there anything else I need to clean out?

[Pipeless416]

you can change it so it shows all PMs in your inbox.. im guessing yours shows PMs from the last two days lol.

[Brauap]

Nope, I have it "From the Begining". But, I went to PM's Sent and deleted that all, and I got a PM, so I guess that was all.. :cool:

[BlasterEaten250]

Originally posted by Pipeless416
well since i already have a thread with random stuff in it, i'll keep posting in here. i finished the mounting spacer for my brothers w/b e series today. here it is..it needs to be polished too. sweet:cool:

[AnDy7]

Pipeless416 check your PM's

[Pipeless416]

checked, but i forgot to reply. i'll try to get you the solidworks plans i have. if you don't have solidworks, you can just download the viewer. give me a couple days cuz they arent on my computer. i'll also have pictures soon of how it all fits.. if it fits lol.

[AnDy7]

alright cool sounds good

[Pipeless416]

its done! i'll have more pictures of it installed tomorrow or saturday.

[Pipeless416]

2

[Pipeless416]

3

[Pipeless416]

last for now :D

[08400EX]

Mike,

Looks great, you did a very good job on that!!

[Pipeless416]

thanks for the compliments 08400EX! i appreciate it.

[White400]

I just built an airbox for mine out of diamond plate aluminum. Just got it done today. Will get pics up soon. But did you have any trouble trimming the airboot? You know where the snorkel used to go into the airbox? Mine is actually a one-piece boot for the intake tube and the snorkel. One 8 shaped looking hole in the stock airbox. I plan on just cutting it off and trimming it a bit...just wondering if there were any obstacles I should be aware of. Nice looking box though, I like the powdercoat. Think I'm just gonna polish my diamond plate.

[Pipeless416]

sorry about the delay everybody.. stupid dsl modem went out. anyway, i got the box installed and it works great. i also went up to black river falls, WI today and abused it over 130 miles :) . it held up great! and white400, that sounds really cool. for the air boot, i just used a hack saw to cut off the snorkel, and then a grinding disc dremel bit and tool to shave down the rubber so it will mount. it was pretty much straightforward from there on out. can't wait to see pics of yours!

[Pipeless416]

my airbox held up today.. but my axle is a little tweaked now. :o

[Pipeless416]

right side..

[Pipeless416]

i really wanted to mount the rectifier in the caliper cutaway section, but the stock wiring isn't long enough.. looks like i'll be messing with yet another thing. :devil:

[Pipeless416]

last one of the box.. i need to take it apart again and bring it back to school when spring break ends so i can turn it in! haha

[Pipeless416]

heres a shot of the dash i made all mounted up. its still not polished, but it sure does serve its purpose! Brauap, i'll see what i can do for you lol.

[Pipeless416]

whoops, thats not the dash shot.. oh well, its my thread and i'll do what i want haha :blah: heres what i meant to post.

[my88r]

looks good.:) is the rear shock spring full soft.

[Pipeless416]

thanks! and yes i got rid of nearly all the preload and slowed down the rebound a bit. now it doesn't kick me in the butt over whoops lol. it really gave it a much better feel with almost no bucking and it still doesn't bottom out. i don't know why i waited so long to mess with the adjustments.

[my88r]

looks like my shock is coming off now.lol went to florida to ride for a week the sand whoops tore my back up. even when i was 3rd -4th gear pinned across them.:grr:

[Pipeless416]

Originally posted by my88r
looks like my shock is coming off now.lol went to florida to ride for a week the sand whoops tore my back up. even when i was 3rd -4th gear pinned across them.:grr:

haha sounds like my experience at little sahara. whoops are my favorite, but they're not much much when it feels like the back end is gonna come up even when tapped out in a higher gear.. my arms and back hated me for a week. if you get rid of some preload and slow down the rebound you'll thank yourself the next time you hit a nasty set of whoops.

[BlasterEaten250]

Here is the mount you made for me on it.

[Brauap]

Originally posted by White400
I just built an airbox for mine out of diamond plate aluminum.

X2! :devil:

[Pipeless416]

Originally posted by BlasterEaten250
Here is the mount you made for me on it.

cool, i'll collect my check later.

Originally posted by my88r
looks like my shock is coming off now.lol went to florida to ride for a week the sand whoops tore my back up. even when i was 3rd -4th gear pinned across them.:grr:

welcome to Florida lol. If you know places well enough and venture way off from main trails you can find nice smooth trails. Dirtbikes and 2 strokes are the main cause of the whoops to be so bad in Florida. It takes so little effort to build something up in sand on and off the gas like them pingers are what tears up everything. If you see experienced dirtbikers like the pros or experienced 2 stroke riders then they wont make the whoops. Ha when Pastrana, Nitro Circus crew, and Team Factory Suzuki riders were riding where I normally go it became flat in the pit because they would plow the whoops basically and fill in the areas from going so fast over them all day.

[skott1576]

im in the process of makeing an aluminum airbox based off the design of yours. i was just wondering if you could give me the demensions you used to make yours thanks scott

[Pipeless416]

i figured out TIG welding.. and i already have 3 of the sides cut out for a new aluminum airbox..:devil: and skott1576- i'll get the dimensions for you on monday when i can get to them from my shop locker.

[Brauap]

What!? You are cutting off the sides w/ the old weld, just to re-weld them?! wtf? lol

But yo already got it powdercoated and got it all nice looking!!

Well, its your's not mine.. :huh

[Pipeless416]

Originally posted by Brauap
What!? You are cutting off the sides w/ the old weld, just to re-weld them?! wtf? lol

But yo already got it powdercoated and got it all nice looking!!

Well, its your's not mine.. :huh

no brauap.. i'm making a new airbox out of aluminum. my powdercoated one is steel. im just replicating the dimensions of the other one now that i have been practicing tig welding for a little while. those are just my practice welds from today.

[Brauap]

ooohhh.. alright!! I understand! That must be soo much fun.. going to school for that. I wouldn't mind going to school if I got to do that! haha

[my88r]

pipe definitely some nice welds. welding is a very good trait to learn. i went to a tech school for carpentry. my 11-12 year. we built a shed the first year. the second year we built a moduler house.

[Pipeless416]

thanks my88r, and those sound like awesome projects. brauap, as fun as it would be, im not in school for fabrication. i'm actually working towards a degree in construction management. the class i do this stuff in is just an elective.

[Pipeless416]

heres some progress pics of my new aluminum airbox. the welds aren't perfect, because i kept holding the filler rod too far down, so i ran out before i could finish the weld :rolleyes: . i'll just sand down the ugly parts and redo it. so far, i'm happy for it being the second day i have ever TIG welded haha. im going to do welds on the inside of each corner too. its sure a lot lighter than the steel airbox!! but i like the looks of the steel one too... thanks for looking.
http://img164.imageshack.us/img164/9681/aluminum1ad5.jpg (http://imageshack.us)
http://img403.imageshack.us/img403/8366/aluminum2hb3.jpg (http://imageshack.us)
http://img245.imageshack.us/img245/640/aluminum3yc2.jpg (http://imageshack.us)

[Hondamaster5505]

looks like its coming out nice.

Ever consider making a couple of them and selling them? I might actually be intrested.

[Pipeless416]

Originally posted by Hondamaster5505
looks like its coming out nice.

Ever consider making a couple of them and selling them? I might actually be intrested.

thanks, but once i finish up this one that'll be it, due to the free materials and time constraints. once i decide which one i'm gonna use i'll probably let my brother use the other one if he wants it.

[Pipeless416]

heres a few pictures of the nearly finished aluminum airbox i've been working on. all it needs now are the brackets. the box will be polished when its all done, so it looks a little rough now. i haven't quite decided if i want to bolt on pc'ed gloss black steel brackets, or just weld on 1/4" thick aluminum brackets. i'm just trying to make this thing bulletproof.. if you haven't noticed by the gobs of welds lol. they're not the prettiest, especially on the inside, but i can't complain when its free, and im still relatively a beginner.

[Pipeless416]

back

[Pipeless416]

i'm pretty proud of the caliper cutaway section.. :) i'm still working on inside welds.. they're hard.

[Pipeless416]

last one for now. i'm also gonna sand down the long bottom weld. that one is really ugly. well, half of it is.

[AnDy7]

hey, looks nice:macho and trust me aluminum can be tricky to weld and the melt through on the back side is supposed to be there (good penitration) looking good

[Pipeless416]

heres some updated pics. i haven't had a whole lot of time to work on this, as i have been working on my brother's e series bracket. i made a new battery bracket for this one, and it just kinda holds the battery in place by wrapping all around it. i also decided to use a steel bracket for the back of it, and it is bolted on. it will never break. :p

[Pipeless416]

the round plate will help distribute the load better and keep the bolts from possibly pulling through on a hard impact. the actual bracket is rounded too on the other side.

[Pipeless416]

im going to leave the brushed look on the inside and polish the outside. anything steel will be powder coated or sprayed.. depending on time.

[Pipeless416]

.

[Brauap]

Looks real good! Wish I could do that! Hey looking at your last pic I realized what was in the background, I can't believe you actually go on the "ATVRiders.com" PPsshh... looser.. lol jkjk

[250x_kyle]

looks good im goign to GTAW up an airbox and posibly an oil tank for my hybrid in the next week or so depending on when i get the time at school. keep up the good work.

[Pipeless416]

an oil tank would be awesome. post some pics of everything when you're done.

[Brauap]

Hey, pipeless, if you think your up to making an oil tank, I'll buy it off you. Dont care the look, I just want it to beable to hold 4quarts.

[250x_kyle]

Originally posted by Pipeless416
an oil tank would be awesome. post some pics of everything when you're done.



will do. probably wont be for a week or to for the oiltank because im just now going to send payment for my hybrid motor, and im welding up 6 boxes for a rig. should turn out nice.

tip on the tig welds. make the tungsten flush this the cup with a good ball on the end. then i normaly rest the cup about 50 50 on the base metal in those 90 degree angles. press the pedal in full way till it starts to melt the back off to about 3/4 pedal to half pedal. works for me.

brauap why do you want it to hold 4 quarts?

[Pipeless416]

Originally posted by 250x_kyle
will do. probably wont be for a week or to for the oiltank because im just now going to send payment for my hybrid motor, and im welding up 6 boxes for a rig. should turn out nice.

tip on the tig welds. make the tungsten flush this the cup with a good ball on the end. then i normaly rest the cup about 50 50 on the base metal in those 90 degree angles. press the pedal in full way till it starts to melt the back off to about 3/4 pedal to half pedal. works for me.

brauap why do you want it to hold 4 quarts?

i tried backing the tungsten up, but the only thing is i didn't have enough room in the box for the entire electrode. it was always a little bit sideways because the box is too small. a brauap, sorry bud, but i think im done for the semester after this because i'll be out of time. i'll still have access to the shop next year though. im thinking a new rear skidplate.. :devil:

[250x_kyle]

i can understand that. id have welded the sides on first then welded the ends on and not woried about the corners the out side welds would have been plenty. once you learn it its easy. just takes time. ill try to get a sample of my tig weld up here this week or next.

[Pipeless416]

got the brackets put on.. i just need to even them out and put some holes in them. all thats left is getting a bigger hole for the wires and polishing!

[Pipeless416]

i ran a bead at the bends on each one of them so i don't get any cracking problems

[Pipeless416]

shot from the back on the other side.