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badger air box mod

p.ludlow

p.ludlow

Joined Nov 2008
148 Posts | 0+
newark
Brought a 8mm thick camping mat some glue and gay lube to do the mod.Printed badgers thread on how to do it.Can anyone tell me do the double strips of foam go all the way around the air box with extra foam put ontop at front and rear.
 
Have a look at my photo's when I did the "badger box" here

Foam goes all the way round untill you get to the front where you have to taper up towards the front mount, then make a piece that is fixed under the mounting screws. The rear (second layer) was cut with a higher part that seals the odd shaped recess of the tank. Clear as mud eh :biggrin but the pictures show how I did this I think. Any questions ask away mate and good luck :thumbup
 
:confusedWell had a go at it today, dont have a garage so had to brave the cold.Not sure if its the right glue,taking along time to stick,maybe too cold.It goes clear after 24hrs,think i used too much,going to put cover on and give it till tomorrow to set.
Does the piece at the front just lay there held by screws,did not glue this bit,and do you think i need more at the front sides.
Picture003.jpg
Picture004.jpg
 
Just checked the foam and the bloody glue still not stuck,this stuff is ****.Got some no nails in the shed,do you think that would do the job or any ideas to what will stick this thing down.
 
If you look at my second photo you can see how i've done the double thickness right up to the mounting plate, and on the last one the front piece sits on top of that whereas yours stops short on the second layer. This might leave a gap when you lower the tank. I also trimmed the square edge of the foam so it was bevelled to make it easier when lowering the tank (hard to see from my photo's :roll)

Also, you have stuck an extra piece on for the higher back part, whereas I incorporated that into the second layer. You'll know if its ok when you try lowering the tank whether it's too tight because of the extra thickness. Plenty of vaseline before you lower the tank down, then check that you have a good seal by checking that the vaseline has transfered to the tank wall.
I didn't have the problem of drying glue as the foam i used was sticky backed. Is that the type of glue that when it drys it's like rubber ?

Just read your last post...i wouldn't use no-nails you'll never get the stuff off again lol. Give it untill tomorrow and see if it sets overnight.
 
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Cheers for those points sprocker,i will stick a small piece in the front.The back piece i think badger just stick extra high layer on top of the double so was lazy there,not too good at craft work.
Just checked the glue still not set on air box but stuck foam together,its a craft glue never used it before,maybe needs time because bike outside and weather.When you cover it in gay lube,if it needs more foam putting in,how will you glue it when the foam has been covered in gay lube.Wished i went for a faster glue tho,just worried some glues might melt the foam.
 
Gay lube :lol dont forget to put some on top of the filter too :thumbup you've probably got enough foam on, wait and see tomorrow and worry about it then :biggrin
 
sprocker said:
Gay lube :lol dont forget to put some on top of the filter too :thumbup you've probably got enough foam on, wait and see tomorrow and worry about it then :biggrin
Click to expand...
:thumbup:thumbupGot 2 large tubs of gay lube,99p each from the 99p store.Good job you said about filter,was only going to put it on sides of air box.Got to go out tomorrow so if not set by sunday think the no nails will be out.:biggrin
 
:jackThat glue is **** still not set.Got up early and done it all again before i go out.Is this any better sprocker,used no nails this time,get the gay lube out tomorrow.:biggrin
Picture001.jpg
Picture002.jpg
 
Thats a much neater job mate ( you could probably trim that back piece down by about half height tho') :thumbup

Once the tanks fitted you'll see where you have to trim the front piece too so thats it's all hidden out of sight. Roll on gay lube time :pirate
 
sprocker said:
Thats a much neater job mate ( you could probably trim that back piece down by about half height tho') :thumbup

Once the tanks fitted you'll see where you have to trim the front piece too so thats it's all hidden out of sight. Roll on gay lube time :pirate
Click to expand...

Has anyone had a bike on the dyno after doing this mod?? What is the performance gain?
 
I never did when i had this on, But i think badger did. I think it gives a better mid range dan. Certainly felt "freer" when giving it some beans :biggrin
 
sprocker said:
Thats a much neater job mate ( you could probably trim that back piece down by about half height tho') :thumbup

Once the tanks fitted you'll see where you have to trim the front piece too so thats it's all hidden out of sight. Roll on gay lube time :pirate
Click to expand...
:thumbupCheers will trim back piece down in the morning,do i have to lube that back flap and the flap that sits at the front,or is it just the sides and top of filter.Must be ready for my blue peter badge.No good with gay lube tho:biggrin:biggrin
 
lube it all over to make sure it seals all round :thumbup

You sure your no good with the lube ? you bought two jars....large ones at that :eatcorn

:biggrin
 
sprocker said:
lube it all over to make sure it seals all round :thumbup

You sure your no good with the lube ? you bought two jars....large ones at that :eatcorn

:biggrin
Click to expand...
:thumbupCheers for that,does the back flap foam fold to the front when you lower the tank or do you fold it to the rear and lower tank.Can not wait to try it out,did not take foam off from under tank,hope it dont take a lot of the induction noise away.:biggrin
 
p.ludlow said:
does the back flap foam fold to the front when you lower the tank or do you fold it to the rear and lower tank.
Click to expand...

Never touched it, it wil fold slight forward but only in line with the tank shape. Lift the tank back up after lubing the foam to check it has transfered to the tank, this will tell you you have a complete all round seal :thumbup
 
sprocker said:
Never touched it, it wil fold slight forward but only in line with the tank shape. Lift the tank back up after lubing the foam to check it has transfered to the tank, this will tell you you have a complete all round seal :thumbup
Click to expand...
:thumbupCheers,Fitted well when i lubed it but the outer layer of foam came away so i have binned it all and done it again.Too much lube about to try and re-glue it,so thought best to do it all again.I am having a really bad time with this glue lark, must be to do with weather and bike left outside.
Going to leave the no nails glue a week this time for it to really set before i lube.2 jars came handy in the end.:biggrin
 
Oh dear :dowhat did you trim the edges as said before so the tank has a lead-in when lowered :dunno
 

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