How to make your own air box lid pre-filter (step by step)
NOTE: This was first posted in the 400EX section, but I had some people over they mention that I should post it here for everyone else to see. Also, I'm sure this will work for other quads, not just the 400EX, you just have to see if EHS makes the filter and then order it. Make sure you tell them that you just want standard shipping, so that will save you a little bit more. Take your time and you'll be fine. Thanks for reading this. Any questions, please ask!
Max
I'm cheap. I don't like to spend money on stuff unless I really have to. So, when I saw the EHS air box pre-filter I thought I could make one myself. I ordered the filter from EHS (since that is the hard part to try and make a filter) and then went to work. If you are handy you should be able to do this with out much problem. Just take your time and be careful. The only thing that I needed on hand was a sheet of thin aluminum and some bolts, washers and lock-washers. The filter from EHS only cost $17.00 for regular mail.
NOTE: Here is a link to a .PDF that I made of my template, so now all you need to do is print it out and cut it carefully.
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http://www.maxfior.com/atv/400EX/MOD...X_template.pdf (right click as save it to your desktop or where ever)
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Here is the sheet that I used, you want to make sure that it is the right size.
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Filter looks like it'll fit nice. Now it's time to make a template, I used an old folder that I found lying around. Just take your time with this.
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Looks good, now it's time to cut the middle out...
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When using trusty razor blade make sure you be careful... You don't want to cut your fingers or face off... Then you won't be able to pull wicked hole shots in the summer time!
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Now with the middle out you can work on tracing to the metal sheet. Tape it in place and then get out the marker.
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Trace away...
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After the trace job, clamp that sucker down and get out a 1/4 inch drill bit for making the holes. You'll also want to pop a hole at an edge for getting the scroll saw started...
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Holes drilled.
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Hole to start the middle cut with your scroll saw.
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Middle cut out, now it's time for the sides...
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Take your time when cutting out the rest... Make sure to re-position everything when cutting and clamp it down really well so that vibration is kept to a minimum.
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The cutting is finished and then I made sure to clean any sharp edges off... Don't want to cut anything...
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After the sharp edges were removed I then clamped the metal to the air box so that I could punch 1/4 holes properly.
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I also made a hole in the middle to start the saw... Now I carefully cut out the middle. Taking my time...
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Now that the middle is removed I clean the burrs off and get ready to assemble everything. Make sure that you use good bolts with washers on each side with a lock washer on the inside before the nut.
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Finished product... Looks pretty okay if I do say so myself... Now with the money I saved I can go buy some lunch, I'm hungry...
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Bottom view.
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Ready for action!
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Any questions, please ask! This might not be for everyone, but I like to make things when I can. Good luck!
Max
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