Cold Air intake done

[Firefly]

Didn't feel like riding tonight - so it turned into a Friday night mod night. Decided to finally finish my cold air intake by building an insulated box to go around the Evoluzione Race airflow system.

I had two goals - reduce intake noise and keep cool air going into the system.

I built the box out of air ducting and wrapped everything in special race insulated heat/noise barrier with self-stick back. Neat stuff - REALLY sticks. Used some velcro so I can remove the box whenever I need to clean the filter.

I was hoping for a 50% reduction in intake noise - and I think I came pretty close as I can now hear my Hindle for a change!

I didn't have enough of the high-temp black duct, so I did one side with generic 3" dryer duct - which I was using before just to bring cool air in closer to the filter system.

Not as pretty as I wanted--- but not too bad for a few hours work.

 

[Blinc]

Hey Firefly,

Looks great man!
I would like to do something like this to mine also, so have a couple questions...
Where do you get the insulated heat/noise barrier stuff also the high temp black duct, AND, seems like you would pretty much be smashing down the red foam as there is barely any room between the top of the red foam and the frame, and by doing that and by enclosing that unit, how are you actually getting enough air pushed into the new airbox design? I mean, I know the engine vacuum will suck the air in, but seems like instead of a 360 air intake, you have to rely on 2 tubes...wonder if that is enough or not really an issue?

 

[Firefly]

Here is the heat shield stuff:

http://www.hrpworld.com/index.cfm?form_prod_id=309_4473&action=product


The ducting I got on ebay I think--- or maybe carparts.com.

The heat shield stuff is pretty thin---- 1/8".

I thought about the '360' air also- but decided I would rather have cool air and less noise - and I'm sure my setup is still FAR less restrictive than the original BRP air/oil box unit.

No difference in performance from what I can tell - bike feels just the same as before - only more quiet. The left side (sitting on bike) has a plate that is velcroed on the end -so all I have to do is pull that off and then slide the box off from the right side in order to service the filter.

I sized everything such that it just touches the red foam filter without much compression - none on the sides - maybe a little on the top - but not enough to worry about. I also taped up any sharp edges with DEI heat tape so as not to damage the filter.

I think with 2 tubes - each 3" in diameter feeding the new box there should be plenty of air to spare.

I also used some of the leftover heat shield on the top of the bike frame and the top 'Y' shaped panel.

You have to watch the panels and allow room for them - I had to trim the box down from my original design in order for panel clearance.

That DEI sticky shield stuff is really neat - very heavy-duty - but you can bend it. If I did it again, I would be temped to just stick the DEI heat shield back to back.

Let me know what you come up with.

The vents are a stainless steel marine cowl I got from a marine supply online. Still thinking of painting them - but the stainless steel looks pretty good - in fact most people never notice the vents at all.

Let me know if you have any other questions - I can send you more pics next time I take her apart.

Still not sure if I like modding or ryding more !

 

[Blinc]

I think I will try the DEI back to back like you mentioned. Do you think the 4ft by 21" will be enough material?

I could not really tell where you have the vents exactly, I am assuming in the fog light holes?

Do you happen to have the dims on the box you made?

I would also love to hear my Hindle again, so I appreciate all the help!!

 

[Firefly]

I think I will try the DEI back to back like you mentioned. Do you think the 4ft by 21" will be enough material?

I could not really tell where you have the vents exactly, I am assuming in the fog light holes?

Do you happen to have the dims on the box you made?

I would also love to hear my Hindle again, so I appreciate all the help!!

The 2ft x 21" was plenty enough for me - still have a little 7x7 square leftover - although if I had the bigger one I would have covered other things up too!

I'll measure the box sometime this week when I pull the panels off again and post the dimensions here.

I have actual fog lights, so I have to cut some holes and put vents in the Spyder. You can see one side in this photo. The black duct goes over to the clutch side - and up underneath the silver duct that goes to the other side. I used stainless steel marine cowl vents. Might paint them - not sure yet.

You'' have to decide if you think the back to back DEI version will work - it's pretty strong stuff. I cut the sheet metal to size with room to spare (not much) and then stuck the DEI stuff on the outside and inside - so the only real difference would be that I have the sheet metal in between. You could use plastic too- whatever is easiest for you to work with.

So far this is working just great- I put CHAD Sr. back on the bike last night - so I don't have any wind-in-the-helmet noise to block out that intake noise--- and it's for sure MUCH quieter. Bike runs just as good as ever.

 

[Firefly]

Hey Blinc. I measured the box today while I was tinkering with some other stuff. These are approximate-- but pretty close.

11" length (side to side on the bottom)
8" wide (Front to back)
3.5" tall

The slanted top part starts about 7" from the left (clutch) side.

Hope that helps.

Zero problems thus far. Next oil change and filter clean I'll take a ride without the box and with to hear the difference-- but that's about 1,500 miles away--- so maybe a month.

Over all I really like it- it was worth doing and makes the race airflow noise MUCH better.