homemade prefilter lid, (easier than most)

[tri5ron]

Hi guys,
I know it is nothing new to cut the stock airbox lid and install some Outerwears material.

Most guys that I have seen do it, usually make a aluminum "picture frame", and use bolts/glue to hold it in place. That is fine too, it works well, and I'm not saying mine is any better.
I just wanted to do it from a different approach, getting a few more square inches of coverage, have it be an easier mod to do, as well as it being easier to service.
hope you enjoy...


First I cleaned the lid with some Goof-off to get any oily residues off of the plastic. Then I used some sticky backed Velcro to make as large of a "frame" as possible, while keeping the Velcro on flat/straight surfaces. I used the "hook" side on the lid.
http://i111.photobucket.com/albums/n148/tri5ron/03%20400ex/IMG_0131.jpg


Next I applied the "loop" side of the Velcro onto the lid, removed the backing tape to expose the sticky adhesive, and stretched the Outerwears material over it. Doing it this way, assures that the Velcro is properly placed on the Outerwears material, And that it is fairly tight and straight. Then carefully remove the Outerwears material, being sure to keep the Velcro stuck, and not peeling off of the material....
http://i111.photobucket.com/albums/n148/tri5ron/03%20400ex/IMG_0133.jpg



Next I trimmed the Outerwears with some scissors, cut out the lid with a saw, and fine trimmed the lid with a rotory file and razor blade...
http://i111.photobucket.com/albums/n148/tri5ron/03%20400ex/IMG_0136.jpg



When my wife gets home, I will ask her to pull out the sewing machine, and do a nice double stitch around the inside and outside edges of the Velcro strips, and Viola! a nice fitting prefilter lid for the stock airbox...
http://i111.photobucket.com/albums/n148/tri5ron/03%20400ex/IMG_0137.jpg

http://i111.photobucket.com/albums/n148/tri5ron/03%20400ex/IMG_0138.jpg

http://i111.photobucket.com/albums/n148/tri5ron/03%20400ex/IMG_0142.jpg

[dariusld]

I think that is a excellent job. I wanted to do mine like that, but was afraid of sand puddling up there. Oh I forgot the "I'm lazy" part.

[Ba9801]

Looks great, that looks alot easier to service than mine.
I had done the one on my wife's Warrior with the aluminum frame. I have to unbolt the frame if I want to do anything with it.

http://i247.photobucket.com/albums/gg138/ba9801/1987%20Yamaha%20Warrior/DSC01423.jpg

[honda400ex2003]

very nice ron!!! looks like a factory lid. steve

[Bill Fuller]

Did the same thing to my quad back in March before we went to Dumont Dunes. Good luck on the sewing part, sewing machines don't like the goo that holds the loop on the Outerwear. Only problem I had is the other side of the velcro thats attached to the box will pull up after a couple of times.

[tri5ron]

Originally posted by Bill Fuller
Did the same thing to my quad back in March before we went to Dumont Dunes. Good luck on the sewing part, sewing machines don't like the goo that holds the loop on the Outerwear. Only problem I had is the other side of the velcro thats attached to the box will pull up after a couple of times.
True that on the glue goo.
I ended up taking it to the local shoe repair shop.
$5 bucks and it got all sewed up nicely.

[Shawthy33]

Did all of you guys that did this airbox mod already have jetting and exhaust on your bikes?

I know I'm close to going down that road anyways but wanted to ask how this paired up with modded exhaust/jets vs stock.

[250ex 2010]

Hey bud, not to be a jerk but this thread is from 2009. But to answer your question you may see some improvements with this mod over stock, but it is giong to benefit most paired with an exhaust. Better inflow-better exflow. IMO i would save this mod till after you have a slip on and of corse jet accordingly.
Matt.

[Shawthy33]

2009 - Good point, not sure why this was up at the top of my thread list or if I got to it from a link.

Either way, I agree, general air flow you need to have start to finish.

[Drfat400ex]

Is the stuff K&N uses for their pre-filters the same as the outerwears materials as far as filtering? I have a powerlid and my friend said he would buy it for new price without the pre-filter it came with so if I could do this with it that would be great.

[tri5ron]

Originally posted by 250ex 2010
Hey bud, not to be a jerk but this thread is from 2009. But to answer your question you may see some improvements with this mod over stock, but it is giong to benefit most paired with an exhaust. Better inflow-better exflow. IMO i would save this mod till after you have a slip on and of corse jet accordingly.
Matt.
It was only brought back up, because I provided a link in another thread.

The info. is still beneficial to new members who may be looking for budget minded performance mods.

Don't be so quick to judge those, who are looking to gain advise from the more experienced and knowledgeable members.
You might be surprised at what you can learn.... and how we can save you some cash.

[250ex 2010]

Originally posted by tri5ron
It was only brought back up, because I provided a link in another thread.

The info. is still beneficial to new members who may be looking for budget minded performance mods.

Don't be so quick to judge those, who are looking to gain advise from the more experienced and knowledgeable members.
You might be surprised at what you can learn.... and how we can save you some cash.

Sorry about that i didnt mean it like that in any way. after all he was searching rather than starting a new thread like everyone else likes to bash people for... i've learned more from this site than anywhere else, by searching. I shoulda worded that better, i absolutely hate when people get on here and bash people that are just trying to get help. Shathy i apologize if it was taken in a wrong way. Tri5ron you should be paid for providing the knowledgable information that you provide this website with. People like your are why this website is so strong. I also dislike when people get judged by how many posts they have, rather than their knowledge..
Matt