Which Outwears for air box lid?

[tywebb3]

I want to make a home-made outerwears airbox lid. Which outerwears will give me enough material to work with? If I just order a 2nd one the same as used on the filter in the box....would that be big enough? What are you guys using?

[NacsMXer]

You can just order the Outerwears airbox cover for a 400EX. Plenty of material to work with. Here's one on Ebay: http://cgi.ebay.com/ebaymotors/Outerwears-Air-Box-Airbox-Cover-TRX400EX-400EX-400-EX_W0QQitemZ200387668153QQcmdZViewItem?rvr_id=&itemid=200387668153

[bmid450]

dennis kirk sells sheets 12"x12" ,18"x18", and bigger,its the cheapest way to go

[rcatvrider]

I bought the outerwears cover itself and went from there.
http://i132.photobucket.com/albums/q16/tamiyakid/400ex/newcam024.jpg

[TRXRacer1]

Who attached it with velcro? I thought that was the slickest way to go about it that I've seen.

[tri5ron]

Originally posted by TRXRacer1
Who attached it with velcro? I thought that was the slickest way to go about it that I've seen. that was me,
here ya go...
http://www.exriders.com/vbb/showthread.php?s=&threadid=408729&highlight=outerwears

[tywebb3]

I found a flange I could use in my scrap pile. It has a little over a 3.5" ID. That should let enough air in....right?

[f4iracer]

I'm thinking about doing the velcro, would that hold without sewing it? I've got some strong heavy duty black velcro.

[tri5ron]

the goo-glue on the velcro has 2 undesirable properties , but are easily rectified.

1- it will hold for a while but eventually pulls loose from the material.
2- it is too gooey for the average home sewing machine to do the job. (it sticks to the needle and causes the machine to bind.

To do the velcro/material thing,
stop by your local shoe repair, or upholstery shop (auto or furniture), canvas shop, or convertable top shop.

and ask them to sew around both edges of the velcro. they will usually do something that small and simple for $5 - $10 bucks.

Before applying the other side of the velcro to the airbox,...

Make SURE you clean the plastic (box) throughly.
First with something like acetone (mom's nail polish remover), Laquer thinner, or MEK, then again with a non petroium based solvent like rubbing alcohol.

[RideRaceLive93]

you can use staples around the edges velcro on the air box to prevent it form pullin up

[jasonwayne222]

the one i got from outwears has the velcro sewn on it, i cleaned and scuffed up my air box and used the velcro they sent me and it just peals and sticks to the airbox, it works really good if u take ur time on installing the velcro on the airbox and the thing u got to think about doing it like this is that if u want to put ur stock airbox lid on u can and it wont be cut up, i live in the gulf and anytime i get near the beach im puttin my factory lid on

[rcatvrider]

Originally posted by RideRaceLive93
you can use staples around the edges velcro on the air box to prevent it form pullin up
That will just give an easy place for the velcro to tear. I doubt you would be able to staple through 1/4" plastic anyway.

[rcatvrider]

Originally posted by jasonwayne222
the one i got from outwears has the velcro sewn on it, i cleaned and scuffed up my air box and used the velcro they sent me and it just peals and sticks to the airbox, it works really good if u take ur time on installing the velcro on the airbox and the thing u got to think about doing it like this is that if u want to put ur stock airbox lid on u can and it wont be cut up, i live in the gulf and anytime i get near the beach im puttin my factory lid on
Ya that's how mine came. Only problem with that is velcro only lasts so long. It's not a perfect seal either. I ran a bead of silicone around mine where it is sandwiched before final assembly. Not to mention it's easier to just pop some clips rather than have to line velcro up every time.

[tywebb3]

I'm still curious, would a 3.5" diameter hole/opening in the air box lid be good enough? I was waiting for some feedback before I started cutting up my airbox lid.

[jasonwayne222]

i think it would be plenty, but i would probly get another stock lid off ebay for when u want the protection, why dont u just get a piece of sheetmetal,preferably alluminum, which u can get from lowes in small sheets for farely cheap, and a had grinder with a cutoff wheel and make a flange that will be as big as the top of the lid. but that should be fine tho.

[troybilt]

Here's my first attempt at making one for my 450R. The lid had some funky angles and dips/bends to it made it a little challenging, but I think it turned out ok. All stuff except for the outerwears material came from Home Depot. Less than 30 bucks to make and that included buying a pop-rivet tool too.

[troybilt]

2

[rcatvrider]

Was there noticeable performance gains on the 450 from the outerwears lid? I did a few mods to my 400 at the same time so don't know exactly how much difference the lid made, I'm sure a 450 would need the air more, especially on a piped one like in the pic.

[troybilt]

Haven't ran it yet with the lid. Shouldn't be any difference for me, I'v been running without a lid at all and just an outerwears cover on my filter. I like this route better, keeps stuff out of the box...