Custom Acrylic Airbox Cover

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Jon0341

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Mar 22, 2010
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I have already started my winter projects seeing how I am in upstate NY and there in no more enjoyable riding weather unless you enjoy not feeling your extremities. I have seen this on one of the forums but have not seen a lot or that much info about it. I was wondering if anybody else has ad how it has performed. I was wondering if the lack of the protrusion to create a vacuum will have any effect on performance. Also I ran the hose down the left side just outside the lower airbox cover instead of over the top where it used to be, I think it looks better and cleans up nicely. Is it necessary to put use something such as a rubber strip to get a better seal? I may get some locking wing nuts or just stick with loc-tite. I am also working on cleaning up the lower air box cover by fitting in a custom cut out of acrylic that I will spray with mirror paint and apply some LED’s. Any comments or criticism will be helpful. :D
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Is that the one you actually made, or are those the pictures you found on other forums? I think it looks cool, and I've definitely thought about making something like this myself, but have been hesitant for the same reasons you are. My bike is an 03 so it didn't have that funnel over the filter in the first place, but it also wasn't a flat piece. The 09's stick up a few inches and were flush with the top of the airbox. I don't think there's really any issues with needing a vacuum, but where you could run into an issue is just from creating too small of a gap and restricting the airflow, not to mention if the gap is too thin the air might run in roughly, and the throttle response won't be that smooth. The way to go, if you wanted the clear cover without worrying about restricting air would be to get an 09 airbox, cut out that whole piece that holds the filter on, cut the top off flat, and then find a good glue to attach the clear piece to the top of that. It'll act as a spacer to lift up the clear piece, it'll give you a solid seal around the air filter, and as long as you glue it well enough on the top, it'll create an air tight seal where the clear meets the black plastic. Does all of that make sense?

Another option would be to cut the funnel off of a newer airbox, and attach it to the inside of your clear cover, so the rest would still be clear. The only concern there would be if it ever came loose and dropped down into the velocity stack it could vacuum seal itself, but I imagine the engine would just stall, I don't picture there being any real damage. The cool part of what you're doing though is that you could actually see the valve turning when you twist the throttle, which you couldn't do if you glued a funnel in there.

As far as your other ideas, I'd love to see how it looked painted in a mirror finish. I painted mine silver to match the frame and it makes it a lot easier to see what's going on inside the airbox cover. I thought about doing it with something more reflective, but I wasn't sure how it would turn out, plus I already had the normal silver. I love the LEDs inside the airbox if you can hide them well enough. You could look into some of the EL wire someone on here just used on a helmet, I think that looks a lot cooler than LEDs if they're gonna be somewhere you can see it.

Anyway, just for reference, here's how it looks painted normal silver to give you an idea. I don't normally leave my hose over the filter either, I usually just run it along the left side of the filter so you don't really see it. I know I have pictures of it with the cover on so you can see how it looks, but I think they're on my other computer, so I'll have to post those later.

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Also, what did you use to cut out and clean up the edges of the clear plastic? I've tried using plexiglass for things before and it's always a mess when I'm done with it.

On mine I just used normal nuts that have those locking plastic washers built in. They hold pretty well and no worries about having it loosen up when I'm riding. The air filters have that little indent in the center of the top edge, I bet you could get some really thin rubber tubing and just lay a strip in that groove, and when you tightened the cover down it might make a better air seal.
 
Yes what you are saying makes sense, that was my concern but I still wanted to have this type of setup to get visual of the intake and see the mechanics in operation. Your idea of using the outer airbox rim and gluing in the acrylic center to get the same effect is an awesome idea. Mine is an 09, I am just hesitant of cutting up the stock just in case all didn't go well. I hope to get a nice day to take it out for a test ride to see if I have any loss of power and to see if this setup is choking. I'm figuring if the old setup didn't have funnel setup then it should be fine. The idea behind putting down acrylic and painting is to clear up and smooth out the lower airbox making it more presentable along with acting like a surface to reflect light. I plan on mounting the LED strips on the airbox cover right behind the Buell lettering to hide it and get the glowing effect and not just seeing the individual LED’s shining at you. I like your setup and how you painted it to match the frame; I would have done the same. It looks like it should be like that. I used a Dremel with the 561 multi-purpose bit. I also used sand paper from abrasive grit down to wet-sand to get the glass effect. Then peel off the protective coating when your done. Thanks for the comments
 
I get impatient and always try to use too many power tools that just melt the plastic, haha. I'm gonna pick up a better dremel soon though so that should help with future projects.

I don't like cutting up my stock parts either. I bought a spare airbox off ebay to cut mine up. Still have the original incase I want to go back. I also have the rest of the airbox I cut still in 1 piece. This way when I switch back to my non-transparent plastic I can stick it on and quiet down the airbox a bit. No need to deal with that airbox noise if you don't get the benefit of seeing what's inside.
 
I thought I would have a problem melting the acrylic but with the 561 bit it cut just fine and I had my dremel on full. When I used the sand paper bit to smooth it out I lower the setting to like 6 to prevent from melting followed by hand sanding. Good idea on buying a secondary, I may try and find one and use your idea on attaching the outer stock to an acrylic inner.[up]
 
I always finish sand edges using a bench belt/disc sander. Nice clean edges that are square. To give the acylic a finished look, sand it down with a fine grit, then take a propane torch to the sanded edges. It will end up looking very professional and glossy. Just be carefull and dont over due it with the heat. I've used heat guns with good results too, even those "windless" torch cigerette lighters will work too, but they get hot quickly (the actual lighter) so allow your lighter to cool (or they blow up).

~Mike......
 
Hey Jon0341 or anyone with some info, I know it's only been almost three years since your comments! But I am at a loss. So here's my biggest question, do know any place that will sell a clear/red or any variation of clear air box covers? Second, is there any specific reason why your not running a k&n air filter? Just curious.Thanks for any helpful info.
 

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