Making a lid for the air box(pics)

[Thumpin440ex]

I have been getting a little tired of having to clean the air box out, batt, filter ect after muddy rides. So said wth let me start making a template up for a lid.. Going to do the lid out of stainless or aluminum and polish it, then use a outer wear to pre filter the air.. Also going to do a little insignia on the back half of the lid just to jazz it up some.. Will post pics of it when finished.. Yah I am bored tonight.. So beer and fabbing it is hahaha :D
http://i6.photobucket.com/albums/y216/mangler0075/400ex/ex1.jpg

Only thing that gets me a little is that the filter is not centered in the box, so the cut is not centered either.. I kinda like chit to be symmetrical, but what ya gona do
http://i6.photobucket.com/albums/y216/mangler0075/400ex/ex.jpg


John

[honda400ex2003]

subscribed, looks great so far!

steve

[CJM]

One of these days I might buy one or them boxes since the the battery goes in them.

very cool project thumpin, id suggest you sandwhich the outwears between an extra plate just like the kit they sell for the lids.

btw, with that setup how big a pain in the arse is it to change the filter out, looks VERY tight on the one side.

[Thumpin440ex]

Thanks guys

CJM I am going to make it so the lid can be removed via a bolt in each corner.. :D Yes going to prob do the sandwich deal also ..


John

[CJM]

Still looks like a PITA to change the air filter lol.

Marc

[Thumpin440ex]

I had to fix that, I meant so the lid can be removed.. With out the lid it is pretty simple..


John

[CJM]

Gotcha

marc

[duneslider]

It won't make any difference to the functionality if you center the hole over the filter or not. I too like symmetry and would center the hole for sure. It'll work the same either way.

I like that box, is it the UM box or another? I would like to get all the battery and gunk off the side of the rear subframe.

I was planning on getting the box and making my own prefilter lid like you are doing.

[Thumpin440ex]

I do not believe it is a um box. Not sure what make it is but def a nice piece. One reason I kept the left side a little fatter is that all the wires and all run down that side of the box. So that will cover them.. I still have not made the final cuts in the piece of stainless I am using so the actual cut out may differ some from the template..


John

[duneslider]

Looks like a nice box. Looks nicer than some I have seen.

[Thumpin440ex]

Ok here are some pics.. For the most part I am waiting for the new outer wear to get here.. Box fastens using some bad arse industrial 3m vel-cro on each corner.. Still have to put the foam seal on the bottom edges.. I think I might even cover it in some 3m carbon di-noc.. Turned out pretty good for a little bit of work.. Also decided to center the hole :D

http://i6.photobucket.com/albums/y216/mangler0075/400ex/lid.jpg

http://i6.photobucket.com/albums/y216/mangler0075/400ex/lid1.jpg

http://i6.photobucket.com/albums/y216/mangler0075/400ex/lid2.jpg

[duneslider]

Looks great! Did you just cut it with a grinder, or jig saw? Looks like you made some nice clean cuts. I can hardly tell the hole isn't centered. I think the carbon di-noc would look sweet.

Have you used the carbon di-noc before? I would like to try some to put on the frame where my boots rub but I'm not sure how durable that stuff is.

Seeing this really makes me want to get an aluminum air box.

[Thumpin440ex]

Thanks man. I used a cut off wheel to do it, also decided that I wanted to center the hole., so it is in the center LOL.. Yes I have used the di noc a bunch.. Did some interior panels in my buddies lexus, also did a plate I made for gauges in my truck.. It is some really nice stuff, is very easy to work with, with some heat it can make un real contours.. Here is the plate in my truck that I did for my console, with my gauges in there.
http://i6.photobucket.com/albums/y216/mangler0075/interior/protoc1.jpg
http://i6.photobucket.com/albums/y216/mangler0075/interior/new.jpg

http://i6.photobucket.com/albums/y216/mangler0075/interior/005-1.jpg

Thanks

John

[Thumpin440ex]

Ok so I have since added some weather seal foam to it around the edges, also going to use a piece of super fine stainless mesh to cover the hole(I think).. pics to come..

John

[duneslider]

The real advantage to the outerwear material is it will resist a little water. I don't think the steel mesh will offer much advantage. You find some fine enough to filter dirt but I don't know.

[Thumpin440ex]

Yah I am not sure yet, but I have some 3 micron stainless that I might just go with.. Anything will be better then running no lid at all like I had been doing..


John

[duneslider]

3 Micron is really small, outerwears are about .005" openings so your mesh is smaller. Should keep plenty of crappy out.