5" x 5" x 8" vinyl fence post
http://www.homedepot.com/p/5-in-x-5-in- ... WqojhG9KSM
There is enough material in that section for 12 housings...
End caps
http://www.alliance-express.com/square- ... ert-glides
Was able to order two free samples.
Aluminum flanges, 2" and 2.25" 2 each
http://www.aircraftspruce.com/catalog/a ... langes.php
As requested edit:
CEET Ducting:
http://www.aircraftspruce.com/catalog/appages/ceet.php
And Air Filter:
http://frugalmechanic.com/auto-part/kn- ... 0mg%200200
Assorted hardware from Ace Angled aluminum stock for mounting bracket
And some 1/8" weatherstriping. The u joint nuts were very instrumental in building an airtight box.
Housing was cut to size and hole saw used to create a 2.5" intake opening, which could be offset if you want to experiment, I centered this one...
Lined the opening itch 1/16" walled fuel lie to create a smooth surface for air flow.
The end caps were hole sawed to 2 1/8", and sandwiched between two flanges and secured with #8 machine head bolts and nylon lock nuts. I Chose to put the heads on the inside to have less interference with the filter element fit. A 2" rubber o ring slipped over each inside flange insures a tight seal for filter element. Edges are lined with weather striping for fitment and seal.
The inboard side end cap is a more permanent set up. All four sides of the housing and end cap edge are drilled to accommodate #8 machine head hardware. The flange of the end cap has a u joint nut clipped over at all four sides and provides a solid reinforcement for the plastic edge and of course something to screw the bolt into. This setup also allows to get a secure airtight fit by pulling the flange out slightly against the weather striping. The outboard end cap has weather striping around all four edges and just ne side is drilled, clipped and a single screw holds it snug and tight and makes for easy quick removal for inspect/service.
The housing is painted rust oleum hammered silver, the end caps flat black.
Of the 3 air boxes, this was the easiest to jet. I guessed at 128/42...ended at 130/42. The dynojet needles were at the 3rd notch from the top with 1 shim under them and that's where they are now, the airscrews are at 1.5 turns out but the carbs still need to be balanced and harmonized. The plugs look perfect after a full tank of non-ethanol through them. There was a slight giveback on the lowend but the midrange remains strong and the top end is very strong. The bike really pulls great from 1200 rpms all the way to redline. I hit 75 mph on a surface street here in Naples earlier this week. Fuel mileage is up 10% from the precleaner airbox. This box provides the greatest prefilter airbox volume, 154 cubic inches, versus a 4" diameter tube with only 46 cubic inches, that is based on using the mg 0200 element. All things considered, I like this airbox the best of the three I have toyed with. It was the easiest build, the easiest jet and best performing across the board.. Btw final fitting did require a little filing...
