£15 Air filter box mod

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Steve7959
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£15 Air filter box mod

Postby Steve7959 » Fri Mar 11, 2016 8:38 am

As we all know, the air filter box on some (most) Urals is pretty crap when going through any water above 5 mph and 2" high. Especially the top venting sort that I have on my Dalesman (Gear Up for you state side brothers).

Airbox mod 01.jpg


We all know the problem and I've looked any many of the excellent mods made by other owners. There is no doubt about at, Ural owners are very resourceful. The 'Lefka' box looks excellent, but it's very difficult to source the parts this side of the pond and, if you do find them, they're blood expensive (£60 for the flanges, £30 for the filter, etc)

My existing box has a nice K&N filter in it, but it still obviously has the water ingress problem. I didn't want to ditch/waste the filter so I looked at the potential of modifying the existing box, cheaply.

There's a bit of room above the box and a little behind it. What could be done?

Airbox mod 03.jpg




An online 'ducting' search and I came across these fittings for venting tumble driers etc:

manrose 01.jpg


manrose 02.jpg


.......... mmmmmmmmmmmmmmm ???????????????????

I took the tapered 'appliance connector' and cut of the spigot so that it could be mounted to the air box lid over the inlet hole. I then 'trimmed' the end of the connector across the rear of the lid

Airbox mod 02.jpg



Next was a quick trim of the 90 degree angle piece to shorten it

Airbox mod 04.jpg
Airbox mod 05.jpg


Then it was duct tape it all together as a trial to see if it all worked and fitted:
Airbox mod 06.jpg


Airbox mod 07.jpg


Airbox mod 08.jpg
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Last edited by Steve7959 on Fri Mar 11, 2016 8:46 am, edited 1 time in total.
Steve

2004 Ural Dalesman
'91 Honda VFR 750
'98 BMW F650

Sometimes I sit and think
............. mostly I just sit

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Steve7959
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Re: £15 Air filter box mod

Postby Steve7959 » Fri Mar 11, 2016 8:41 am

The moment of truth was.......

................ would it all fit?

Airbox mod 09.jpg


Airbox mod 10.jpg


You better believe it :clap:

Now it's a case of hot glue gunning the bits of plastic, Nato green paint the white bits and job done.

Hopefully no more (or a lot less) coughing spluttering and stopping dead when going through water or anything above a slight shower of rain
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Steve

2004 Ural Dalesman
'91 Honda VFR 750
'98 BMW F650

Sometimes I sit and think
............. mostly I just sit

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Albuquralque
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Re: £15 Air filter box mod

Postby Albuquralque » Fri Mar 11, 2016 9:49 am

:lurker:
"Put a little gravel in your travel"

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2014 Patrol - Babe the Blue Ox
EFI Map OR 1.02
Throttle Body Vacuum Ports
K&N Air Filter
Raceway 2-into-1 Header (Right Side)
Previous Urals Owned: 2004 Wolf, 2006 Tourist, 2006 Patrol (TOW), 2006 Patrol (TOM)

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Re: £15 Air filter box mod

Postby Mothra35 » Fri Mar 11, 2016 11:57 am

Neat mod for sure, :lurker: :thumbsup:
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Steve7959
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Re: £15 Air filter box mod

Postby Steve7959 » Tue Mar 15, 2016 10:46 am

The finished item:

Airbox 11.jpg


Airbox 12.jpg


Now it's time to fit it back on to the bike.
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Steve

2004 Ural Dalesman
'91 Honda VFR 750
'98 BMW F650

Sometimes I sit and think
............. mostly I just sit

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VWK75S
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Re: £15 Air filter box mod

Postby VWK75S » Wed Mar 16, 2016 5:54 am

:lurker: John
The Ural's made Maine a much bigger state.

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roscoau
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Re: £15 Air filter box mod

Postby roscoau » Wed Mar 16, 2016 6:34 am

Steve7959 wrote:The finished item:

Now it's time to fit it back on to the bike.


I must have missed one detail - how is the plastic held onto the metal lid?
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Albuquralque
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Re: £15 Air filter box mod

Postby Albuquralque » Wed Mar 16, 2016 7:43 am

Looks nice.........:thumbsup:
"Put a little gravel in your travel"

Darrell - Albuquralque
2014 Patrol - Babe the Blue Ox
EFI Map OR 1.02
Throttle Body Vacuum Ports
K&N Air Filter
Raceway 2-into-1 Header (Right Side)
Previous Urals Owned: 2004 Wolf, 2006 Tourist, 2006 Patrol (TOW), 2006 Patrol (TOM)

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Steve7959
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Re: £15 Air filter box mod

Postby Steve7959 » Wed Mar 16, 2016 9:17 am

roscoau wrote:
Steve7959 wrote:The finished item:

Now it's time to fit it back on to the bike.


I must have missed one detail - how is the plastic held onto the metal lid?


Good point well presented..........

.... and actually quite an important detail.

With the new plastic section on the lid you can't get to the head of the bolts that holds the filter in place. I put a small tack weld on the head of the bolts to make them captive. You could probably do the same with epoxy of similar if you don't have access to a welder. It is then possible to remove the air filter holding nuts on the inside without the bolts turning.

The plastic section is then simply placed and secured to the lid with a bead of clear silicon. This not only holds it in place (lightly rough up the painted surface of the lid) but gives a water tight seal between the lid and the new plastic section
Steve

2004 Ural Dalesman
'91 Honda VFR 750
'98 BMW F650

Sometimes I sit and think
............. mostly I just sit

rivers
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Re: £15 Air filter box mod

Postby rivers » Wed Mar 16, 2016 12:33 pm

Looks like a plan. Nicely done.
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Burt1713
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Re: £15 Air filter box mod

Postby Burt1713 » Wed Mar 16, 2016 8:13 pm

Looks like a great mod. Have you been able to try it out yet?
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Steve7959
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Re: £15 Air filter box mod

Postby Steve7959 » Thu Mar 17, 2016 3:46 am

All tried out and it fit perfectly

Airbox 13.jpg


Airbox 14.jpg


It's pretty tight up to the rear fuel tank mounting point but not currently touching. There is potential to shim the air box back a bit with washers and this would keep it well clear
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Steve

2004 Ural Dalesman
'91 Honda VFR 750
'98 BMW F650

Sometimes I sit and think
............. mostly I just sit


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