Hi gents,

Finally got the Tiger booked into A B Garage to have the new head and fr33 cam put on, and all set up for the summer.

However they have urged me to fit my airfilter beforehand.

Its a 2.0 pinto with gsxr600 carbs, and i have one of the pipercross sausage type filters.

The only problem is it is bigger than the bonnet, hence i'm going to need to cut a hole. This bit scares me! I'm bound to balls it up, put it in the wrong place entirely, or somehow weaken the bonnet so much it just snaps when i put it on.

I have attached a load of pics to show my situation.

The way I see it i will only be able to leave about 1" to 1 1/2" across the front side, and the same on the bottom (albeit the bottom does also have a lip that will remain and thus hopefully make it a little stronger.

There is of course a bonnet catch remaining on the corner next to the hole. will the bonnet still be strong enough to cope? Its the standard Tiger bonnet.

how do i cut the hole? I'm thinking, carboard template, transfer to bonnet and cut with maybe a jigsaw (though i don't own one).

any clues?

Martin (a very apprehensive owner)

are you a man or a mouse?? use your teeth!

eeek eek!

i would not use a jigsaw, i would use a dermal type tool.

i have not got a great deal off the bonnet left on the bottom off mine,

air filter
it is an mk through

cheers

stuart

[Edited on 13/4/10 by Stuart_B]

oooooo thats virtually identical, though mine will be slightly further forward. does the bonnet, specifically where that catch is still feel strong enough?

Martin

the more you try to convince yourself you'll balls it up, the more likely your prediction will come true. stop thinking about it, just measure it up properly and go for it.

one tip though is to make the first attempt smaller than you think you need it, that way when you trial fit it you will be able to see which way you need to stretch the hole without leaving any big gaps.

Take your time, Double check everything and you'll be fine

As said use a Dremel or similar
(Dremel do a nice GRP cutter)

When finished mix up some clear resin and coat the edges of the cut GRP
This will stop water ingress into the GRP causing delamination

what you could do, is make the catch, as far forward as you can, if it is hitting the nose cone you can trim the nose cone where the bolts come from.

here are some more pics
here

hope that helps

stuart

i would however turn your filter the other way or people will think you have gone for the cheaper ssodladid brand

Seems i'm on the hunt then for some sort of dremell thingy.

had a feeling lidl may have one in next week if i recall, though cant access they're site to check right now (anyone confirm?).

Also, because i've made the baseplate out of a sheet of Ali, i dont have any way of making the fixing thingys work on the filter. shall i just take them out and put some locknuts in instead?

Cheers already guys.

Martin

the problem with the "correct" way up it the stupid flanges for the bolts to the backplate rotrude even more!! I dont mind it being upside down really. so long as i never get to see it the right way up i'm happy!!

on, my one, i cut 2 off the tags of, and used a little button head bolt, just at the top of the filter, through the back plate. you can not relay see them, as the filter covers them.

see if i got a picture if you need it.

stuart

Martin

I did this a while ago, if you U2U me your e-mail address I will send you a series of 8 pics showing how I did it. Here are the first and last pictures. I used a jigsaw to cut it out and finished off with a sanding drum in a drill (I don't have a dremmel).


Marking out where I want the hole, with bonnet removed, then replaced bonnet and used the ends of tape visible on scuttle and nose as a reference to mark bonnet.


Marking air filter hole

and the finished hole

[img][/img]

I think most of us have been in this situation,as said earlier make the hole smaller working from centre out.I used a dremel type tool which worked really well,also a bit of edging can cover up any major balls ups.
Rescued attachment indy re-fit0751.JPG

the stretched masking tape is a nice idea.

or make a carboard template.

what is the worst thing that can happen?

you will need to buy a new bonnet, hardly gonna cost the earth?

as ^^^ say, cut hole undersize and work outwardrs.

mine is aluminium and I used a nibbler to gradually enlarge the hole in several states.

note that the frotn edge of you filter is very close to the nose cone - I would suggest some strengthening on the underside of the bonnet - eg. bent aluminium right angle strip glued on plus fibre glass reinforcement.

good luck.

U2U Martin...