Harold Bawlzangya Racing

Hybrid Airbox – Version 3.0

This is even more of a hybrid airbox as I’m introducing Honda parts into the mix.  I got most of what I needed from this auction:

eBayHondaAirBox - Copy

(click picture to enlarge)

After making a lot of aluminum shavings, here are the parts needed to put this together:

HybridAirBoxParts

(click picture to enlarge)

The key to making the Honda boot work is this sealing/locking plate:

SealingLockingRing

(click picture to enlarge)

By no means perfect, but not too shabby for free-hand with a router.  There was no way that I was going to be able to make a ring that would be the exact height, width and radius to match the groove in the airboot.  I decided to make the raised ring a little narrower and shorter so that with the help of some black RTV, I would have a perfect fit and seal between the plate and airboot.

LockingSealingRing

(click picture to enlarge)

It fits in to the Honda filter holder like this:

SealingLockingRingInsalled

(click picture to enlarge)

This is the groove the raised ring of the locking plate will be fitting into with the black RTV:

BootRecess

(click picture to enlarge)

Some RTV on the back of the sealing/locking plate and filter holder:

LockingPlateRTV (2)

(click picture to enlarge)

LockingPlateRTV (1)

(click picture to enlarge)

And then RTV in the grove of the air boot:

RTVBoot

(click picture to enlarge)

All put together:

HondaHybridBootAssembled (2)

(click picture to enlarge)

HondaHybridBootAssembled (1)

(click picture to enlarge)

I had plenty of squeeze-out on the inside and outside of the boot, so I am confident I have this all sealed up.

Installing the Pro Seal gasket:

ProSealHybridAirboot (2)

(click picture to enlarge)

ProSealHybridAirboot (1)

(click picture to enlarge)

Installed in the KX airbox:

HondaHybridAirBoxFinished (3)

(click picture to enlarge)

HondaHybridAirBoxFinished (2)

(click picture to enlarge)

HondaHybridAirBoxFinished (1)

(click picture to enlarge)

OilingAirFilter (2)

(click picture to enlarge)

OilingAirFilter (1)

(click picture to enlarge)

Installed:

HybridAirBoxInstalled (1)

(click picture to enlarge)

HybridAirBoxInstalled (5)

(click picture to enlarge)

New Rad Valve:

HybridAirBoxInstalled (3)

(click picture to enlarge)

Plenty of room around the shock:

HybridAirBoxInstalled (2)

(click picture to enlarge)

And now the money shot – the boot clamps right onto the carb without any modifications to the boot or carb.

HybridAirBoxInstalled (4)

(click picture to enlarge)

Advertisements

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s