Join Date: Oct 2009
Location: Eastern Cape, South Africa
A home made billet airbox vn9oo
Ok so here's the thing, what started the thinking on this project was, i recently had my bike serviced at the dealer, i had been thinking of making something like this so 1000km after the service i took the airbox cover off only to discover the air filter did not look as if it had been changed. Bottom line is i had words with the workshop foreman, and vowed it was the last Kawa would see of me for a service.
So i designed my own airbox complete with a new mounting plate, and it would use a standard weber carb pan type airfilter, it sounded easy enough so i bought the material which included
8" outside diameter/OD x 2 1/2" thick 6061 aluminium
8" OD x 1/2" thick 6061
1 off fram weber air filter
the first thing to do was to machine the mounting plate, which entailed facing both sides and maching a step on the forward edge to accept the cover.
I then mounted the job on my my bench top milling machine found a datum point to suit my needs and using the machines dials i proceeded to plot out all of the holes for mouting to the throttle bodies, and for boring the bores for the venturies. The boring was done with a home made boring head and the bores have a tolerence of less than 1 thou" .
I unfortunately did not take photos at this point.
The six mounting holes for the cover were simply pitched on the correct pcd on my indexing head and then drilled and tapped 6mm x 1mm.
The first photo is of the finished mounting plate after anodising it black.
The second photo is the same but with the air filter mounted
Last edited by Slash; 11-24-2009 at 12:09 AM.