Homemade EVO airbox

Has anyone got any close-up pics of their Evo airbox rubber seal ? and do you know if it's a special type of rubber :dunno

I'm having a go at making a copy while the weathers crap. I made a perspex lid to replace the top of the airbox, which will be used to clamp the seal down to the base but i'm not sure what type of rubber or thickness to use :dunno






looking at the evo site, the picture on there shows the seal folding back on itself at the front where the tank fastens but it's not very clear. A close-up piccy of this would be a great help if anyone has any :thumbup



thanks for any help :thumbup

I cant help you any but i gotta say that looks pretty impresive fella, keep us informed what its like when you get her running with it....:thumbup

Nice work there sprocker

Looks a good bit of kit

How does it differ to a normal Airbox?

AREESSMILL said:

Looks a good bit of kit

How does it differ to a normal Airbox?

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It's supposed to give better mid-range. I've tried the "badger box" mod but took it all off when I put the bike in for a service. I was happy with the sound from that effort and just thought I would try and make a different style airbox and the EVO copy looked feasible to acheive, saves me £140, and would look a bit more Professional :devious

Now thats looking good! got my attention

Goingto have to have a look what B&Q has to offer in the way of rubber sheet to make a seal

Thats all the seal is on mine matey, flat rubber, and yes it is doubled back on itself at the front to block the highest part of the tank mould. Wot ya gonna block the top of that filter wid Sprocker ol mate? I'm in the process of coming up with a way to hold the filter down in place correctly to ensure a good seal..i don't wanna rely on the tank pressure alone to keep it in place. This airbox setup definately gives you better mid range punch.

Bit puzzled here guys why you want to use a rubber flap that will not seal properly against the tank due to it not being able to form itself against any irregularities on the underside of the tank, it physically can't do this.

Sprocker, what you are trying to achieve is exactly what you have just taken off, but IMO worse due to not getting a good seal, OK the mod with foam does not look all that pretty, but it depends whether you want it to look nice or perform better.

I know it is good to make things and tinker, i just love doing such things myself, but the performance of the mod has got to be taken into account, remember this is not even seen so aesthetics should not come into it really IMO.

The bike i had the foam mod fitted to did 18k in my hands and never let me down once, it formed a perfect seal against the tank as i could see with the vaseline deposit and dirt collecting on the vaseline outside the box, this was proof it was sealing perfectly, i doubt it if vaseline will work as well on a bit of rubber.

Anyway guys, i am not trying to stop you guys from making your own or improving on the airbox, i am simply putting across my thoughts on what works better so you guys can have your bikes the best they can be.

I did not make my own airbox mods for my 04 & 06 bike, but i did buy a homer ewe airbox mod which is regarded very highly as one of the best if not the best mod, this is it here and yes it works the same way as my mod using foam, give the same result but looks prettier and costs a heck of a lot more.



When i took my bikes to dyno them in March at Frank Wrathall's the dyno guy Richard who has seen many Aprilias on his dyno said he had not seen as good an airbox mod on one of these, he was well impressed with the quality and the simple functionality of it, plus the bonus is it works very well as can be seen here



Anyway, good to see a lot of us are trying to make our own mods on our bikes, lots more satisfaction when it works:thumbup

Yup, must say Badger the EVO seal is a little ordinary, but with K&N heat resistant grease, i can get a clean seal all the way round...truth be it tho, i do like your method better and can see a far tighter seal being possible.

HAs any one asked chippy steve??????

MSmilleR said:

HAs any one asked chippy steve??????

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hahahaha! you silly boy he's off cabinet making for Kawasuki & caught up in developing papermache race sprockets!!:thumbup

heres some pics of the evo the seals about 1mm thick if its any help

AusRSV said:

Wot ya gonna block the top of that filter wid Sprocker ol mate? I'm in the process of coming up with a way to hold the filter down in place correctly to ensure a good seal...

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I kept the foam I used on the "badger box" mod so can re-use that. Filters not going to move anywhere once the tanks back in position.

Badger said:

Bit puzzled here guys why you want to use a rubber flap that will not seal properly against the tank due to it not being able to form itself against any irregularities on the underside of the tank, it physically can't do this.

Sprocker, what you are trying to achieve is exactly what you have just taken off, but IMO worse due to not getting a good seal, OK the mod with foam does not look all that pretty, but it depends whether you want it to look nice or perform better.

Anyway, good to see a lot of us are trying to make our own mods on our bikes, lots more satisfaction when it works:thumbup

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Hi Badger, I see what you mean now about the rubber seal, I managed to get some from work and have fitted it temporarily, and looking at the picture Pointer posted ( thanks matey :thumbup) it does look a bit odd at the front where it's folded back on itself :confused it can't possibly get a complete seal with that arrangement :eatcorn

I like the look of that Homer Ewe ring, is that a foam outer ring Badger :dunno Mmmmm I can see a modification of my modification on the horizon :devious

To be honest, I thought i did a good neat job of the Badger box and was pleased with the results, the thing that annoyed me was getting covered in Vaseline every time the tank was lifted :roll Do you still need to use vaseline with the homer ewe ring :dunno

sprocker said:

I kept the foam I used on the "badger box" mod so can re-use that. Filters not going to move anywhere once the tanks back in position.




Hi Badger, I see what you mean now about the rubber seal, I managed to get some from work and have fitted it temporarily, and looking at the picture Pointer posted ( thanks matey :thumbup) it does look a bit odd at the front where it's folded back on itself :confused it can't possibly get a complete seal with that arrangement :eatcorn

I like the look of that Homer Ewe ring, is that a foam outer ring Badger :dunno Mmmmm I can see a modification of my modification on the horizon :devious

To be honest, I thought i did a good neat job of the Badger box and was pleased with the results, the thing that annoyed me was getting covered in Vaseline every time the tank was lifted :roll Do you still need to use vaseline with the homer ewe ring :dunno

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It is foam with a sort of soft sealing surface on it, and no vaseline needed mate:thumbup

BTW, i luv being smeared in vaselineirate

Badger said:

It is foam with a sort of soft sealing surface on it, and no vaseline needed mate:thumbup

BTW, i luv being smeared in vaselineirate

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i was gonna say that about the vaseline stuff being needed on the rubbers only, tho i used some around my foamy rim :devious

isnt it fun playing with squidgy things and vaseline.. :nana

of course im talking about home made airboxes with foam around the edge, badger box style irate

Wolf said:

tho i used some around my foamy rim

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That has just conjured up some disturbing images mateuke

This airbox debate thing has been going on for about 8 years now i reckon and it still starts new threads..........amazing stuff:eatcorn

Badger said:

This airbox debate thing has been going on for about 8 years now i reckon and it still starts new threads..........amazing stuff:eatcorn

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I've only had mine a year :doug I have a lot to catch up on :biggrin

I've just ordered some of this to try click me

I'll post up the results, and i've given up with the Evo copy. The rubber I used was too thick to form a good seal on the front where it folds back on itself :roll

would it be worth putting mesh or tights round the inlets incase something got through

ginsters said:

would it be worth putting tights round the inlet incase something got through

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Thats exactly why the wife wears them :laugh

Wouldn't they melt with the heat :dunno