Project Thread - Air Filter Build - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 21 (permalink) Old 12-31-2016, 07:50 PM Thread Starter
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Project Thread - Air Filter Build

Ok guys, so... after looking around and being disappointed with the limited air filter selection currently available, I've decided to go on my own and build one. Not that the options are bad, but if someone else has opted for an off the shelf upgrade, there are really only a handful of options and they all carry a hefty price tag as well.

So here's the plan... Take your typical round K&N style filter for a small block Chevy, turn it on it's side and zip tie it to the throttle bodies and call it a day...

I have begun on the build and while I wait for the 9" round air filter to get delivered next week, I got started on construction of the backing plate. I want to keep all of the functionality of the current air box... 2 vent hoses the IAT all being connected to the backing plate.

Plate is pretty much done and now just need to affix it to the back of the filter housing and bolt her up. What do you guys think?

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post #2 of 21 (permalink) Old 01-01-2017, 11:47 AM
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There are 2 or 3 build threads here somewhere where guys made their own intake.

I always like it when people make their own stuff like that. It's very cool.

Yes, I'm a Chrome Whore.

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post #3 of 21 (permalink) Old 01-02-2017, 03:05 AM
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Looking good so far I did something similar for my vn2000

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post #4 of 21 (permalink) Old 01-02-2017, 05:49 PM Thread Starter
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Originally Posted by rocnrol View Post
Looking good so far I did something similar for my vn2000

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That's basically what I'm going with... But a slightly larger variant. Did you do a steel backing pate or aluminum? The aluminum I am using was easy to work with, but wasn't sure how well it would hold up over time. Luckily, due to the size of the filter, I am able to use the 2 previous air box mount holes on each of the jugs for some extra rigidity. So I'm hoping for the best. Lol

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post #5 of 21 (permalink) Old 01-02-2017, 07:01 PM
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Quote:
Originally Posted by Bu$aboy79 View Post
That's basically what I'm going with... But a slightly larger variant. Did you do a steel backing pate or aluminum? The aluminum I am using was easy to work with, but wasn't sure how well it would hold up over time. Luckily, due to the size of the filter, I am able to use the 2 previous air box mount holes on each of the jugs for some extra rigidity. So I'm hoping for the best. Lol
I used the adapter base from another aftermarket air cleaner, then made up an aluminum backing plate

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post #6 of 21 (permalink) Old 01-02-2017, 07:09 PM Thread Starter
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Originally Posted by rocnrol View Post
I used the adapter base from another aftermarket air cleaner, then made up an aluminum backing plate

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Ah I see. And from the looks of it, It looks pretty solid.

I also see you opted for removing the secondary butterfly's... I've been debating on whether or not to do it. I've read a few threads on the subject, but just haven't decided...

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post #7 of 21 (permalink) Old 01-02-2017, 08:07 PM
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Originally Posted by Bu$aboy79 View Post
Ah I see. And from the looks of it, It looks pretty solid.

I also see you opted for removing the secondary butterfly's... I've been debating on whether or not to do it. I've read a few threads on the subject, but just haven't decided...
Yup, it's holding up well. To be honest, I didn't notice much difference with them removed.

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post #8 of 21 (permalink) Old 01-06-2017, 09:57 AM Thread Starter
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Update!!

The build itself has come to an end! The 9" air filter fit perfectly and modifying the backing plate to fit wen't very smooth. All in all, she seems to be breathing great! Thankfully my PCIII also came in and is now all wired up. Now I just have to get a map in there until I can get her on a dyno and properly tuned.

Here is what the bottom/backside of the filter housing looked like when I got it. OBVIOUSLY that wasn't going to work and the raised lip had to go.



Once the work was done to the filter housing, fitting the backing plate I made earlier in the week was easy. Using some quality liquid gasket and running two good heavy solid lines will ensure nothing gets through along with adding some rigidity (and piece of mind) with a few pop rivets... She was ready to mount!



All in all after letting the sealant set, everything bolted up nicely! The leg clearance was pretty perfect as well. Not it's just a giant Chrome disk on the side, and needs something to break it up... not sure what just yet... thoughts?



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post #9 of 21 (permalink) Old 01-06-2017, 10:17 AM
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Quote:
Originally Posted by Bu$aboy79 View Post
Update!!

The build itself has come to an end! The 9" air filter fit perfectly and modifying the backing plate to fit wen't very smooth. All in all, she seems to be breathing great! Thankfully my PCIII also came in and is now all wired up. Now I just have to get a map in there until I can get her on a dyno and properly tuned.

Here is what the bottom/backside of the filter housing looked like when I got it. OBVIOUSLY that wasn't going to work and the raised lip had to go.



Once the work was done to the filter housing, fitting the backing plate I made earlier in the week was easy. Using some quality liquid gasket and running two good heavy solid lines will ensure nothing gets through along with adding some rigidity (and piece of mind) with a few pop rivets... She was ready to mount!



All in all after letting the sealant set, everything bolted up nicely! The leg clearance was pretty perfect as well. Not it's just a giant Chrome disk on the side, and needs something to break it up... not sure what just yet... thoughts?



Good work!! Don't know what to recommend to break up the expanse of chrome, but it was something I was worried about when I was doing mine, which is why I went with the 6"

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post #10 of 21 (permalink) Old 01-06-2017, 10:39 AM Thread Starter
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Quote:
Originally Posted by rocnrol View Post
Good work!! Don't know what to recommend to break up the expanse of chrome, but it was something I was worried about when I was doing mine, which is why I went with the 6"

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I'd like to maybe do a decal or something on the cover. Possibly the infamous "125ci" or something like that. But I would need to have something unique and custom cut.

Do we have any decal makers on this forum?
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