Hi guys,

Im planning on making an ally airbox for my car.

I already have an airbox from a GSXR600 (same as my carbs) for the rubbers, and i have cut around the rubbers to give my self a flat bit to glue the ally on to (word of warning, grinder throwing hot plastic on to your hand stings a bit )

My plan is cut a big rectangular sheet of ally out, cut 4 holes in it to fit around the holes in the plastic and glue the two together. so question one. what type of glue should i use?

Then the plan is to bend just above the rubbers so the top of the airbox is flat, then make a nice round edge bringing it round to the bottom the plastic bit where i will glue and rivet the airbox together.

Next question, what have people done for end caps and an intake pipe? My plan is to run an pipe down to housed filter infront of my engine, and then have cold air ducts to the front of the car.

I will try and draw up a picture to help.

Cheers

Mikkel

heres a VERY quick drawing

The black lines represent engine and carbs (yes my engine is slanted its nots just my terrible drawing ) the red bit is the plastic i cut out of the airbox, and the blue is my airbox idea.

Hopefully you can sort of see what im going for

ETA to the drawing haha

Image deleted by owner

[Edited on 5/8/10 by Miks15]

Be interested to know people's comments actually as I was thinking of doing something similar having

1. seen the price of a replacement pipercorss sausage filter for my knackered one and
2. heard how loud the induction noise is vs my exhaust and worried about the new lower IVA limit.

I was thinking of revietting and siliconing the box together and araldite to fasten to the existing aluminium backplate for the filter.

I know people will comment on restricting performance but how much difference that will make on my rather ancient zx9 engine I don't know!

Rich

yeh ive got some araldite actually, will probably do that!

Anyone done one like this?

Im not sure how to do the end caps? Mabye just the right shape with some tabs bent over, then seal with some silicone and secure with rivets?

Here's my effort made from spare steel I had.


My Airbox
And painted in situ


Painted Airbox

Had to weld a 2mm plate onto the base to strengthen it and on the whole I'm not too happy with it and would prefer to do it again in ally when I find time and can perfect my rough arsed ally welding skills.
On the whole though I thought it felt a little faster compared to my sausage filter although it has messed with my fuelling a bit. Swings and roundabouts I suppose.
Still plenty of time to tinker what with all the rain I haven't barely got out this year.

Just a thought, but if if you were to put an 8mm 90deg fold on the long sides of your rectangle
and then formed the shape you would have a flange on either end.
You could then rivet, or better still screw your ends on.

hth
Paul G

quote:

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Originally posted by 907
Just a thought, but if if you were to put an 8mm 90deg fold on the long sides of your rectangle
and then formed the shape you would have a flange on either end.
You could then rivet, or better still screw your ends on.

hth
Paul G

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