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Author Topic: DIY air filter, what have I started?  (Read 6203 times)

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Offline dharmic

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DIY air filter, what have I started?
« on: November 05, 2017, 02:57:55 am »
G'day all

Been lurking for a while, nothing to contribute until now. Hopefully this is of some use to someone.

So, we're all familiar with the standard filter cover. Ugly as sin, great for smacking your right knee and, as I discovered a couple weeks back, a great way for Yamahahaha to gouge you when it comes time for a filter replacement. You want how much  ::) ;D ;D ?



NO MORE, says I. Down to the local auto part supplier with the idea in mind of a silly cheap replacement filter, ring style, in a two piece holder. Found this one, next to the Yamaha OEM job, for 15 Australian Pesos (about USD12 I think).



Of course, can't just bung it on - need a back plate that matches the throttle bodies.



So out with the graph paper and pencil rubbing to get something to measure up.



Feed into CAD, print, x-acto and test fit. Rinse and repeat - this one took a while because I got myself confused with a slight taper and had a couple key dimensions wrong. But I got there in the end.



Eventually a dimensioned drawing ready to go to the next stage.



Low profile but thick enough to clear the TPS, nice smooth fillets around the intakes, some re-inforcement webbing to stiffen up against vacuum deformation (just in case).



When I bought the bike it hadn't done many miles but it hadn't been looked after, either: most of the chrome has rust coming through. I'll probably need to either get the forks re-chromed or replace them but the headlight cowl, speedo surround, petrol cap, tail light cap etc? I have a notion to pull them, clean them smooth and paint in a copper finish. If I like it enough I'll strip the paint and get them plated and polished.

Anyway, with that copper and black and white colour scheme a steam-punky kinda theme presented itself. This air filter is a good place to try it out!



3D printed in ABS - where it's sitting I don't expect it will get hot enough to have an issue. Ran this test print for a few days and it works well.



Today's mission was to get a bit of iron scrap rod in the lathe and make up a centre bolt that screws into the bottom filter bolt hole on the throttle bodies, and in turn has a female thread on the other end into which I can screw a cap-head SS bolt.

Also painting, masking and painting.



The paint is rough but I'm super happy with the overall effect. So I'll probably do another cover, this time in two parts (one black, one copper) so I don't have such a nightmare of masking to stuff up next time around and the copper vs black demarcation will be bang on.

Thanks for having a look, will post any other changes as I get them done :)
« Last Edit: November 05, 2017, 03:02:35 am by dharmic »



Offline ShakerNorm

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Re: DIY air filter, what have I started?
« Reply #1 on: November 05, 2017, 03:40:35 am »
Looks Sweet! and a great way to save a few $$$ in the process.  You could probably sell them, too.... make your money back!

What did you do with the breather hose?  Since you 3D printed it, it would have been easy to add a nipple to the back to slip the hose onto, so the engine could re-burn the crankcase air.
NOBODY hates winter more than a Canadian Biker!

Offline dharmic

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Re: DIY air filter, what have I started?
« Reply #2 on: November 05, 2017, 04:40:50 am »
There's a few things to do in v2.0

The breather's just floating in the breeze behind it at the moment and is something I need to think about - on the standard box IIRC the breather attachment is outside the filter so I'm not keen about routing it into the clean side of the filter, if that makes sense.

I went to wash it today and well, as it is now it isn't going to be ridden in the rain and the filter needs to be covered for washing. I've put some locating slots in there for a cover later but no prototypes yet ( no rain forecast either :D ).

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Offline ImMrEd

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Re: DIY air filter, what have I started?
« Reply #3 on: November 05, 2017, 05:34:21 am »
Looks awesome, great work! Looking at the last picture, I would’ve kept the inside colour silver to match the rest.
The horse has Bolt'ed!

Offline dharmic

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Re: DIY air filter, what have I started?
« Reply #4 on: November 05, 2017, 06:13:11 am »
Thanks. The plan is to convert more of the silver bits to copper so it won’t be so lonely in time :)

Offline vvance

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Re: DIY air filter, what have I started?
« Reply #5 on: November 05, 2017, 08:14:53 am »
Really nice. Great work!

Offline lunkhead

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Re: DIY air filter, what have I started?
« Reply #6 on: November 05, 2017, 09:52:57 am »
Looking good!
C-SPƎC

Offline ChrisMitch

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Re: DIY air filter, what have I started?
« Reply #7 on: November 06, 2017, 01:48:17 pm »
am i the only one who can't see any photos from the OP?

Offline DelawarePete

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Re: DIY air filter, what have I started?
« Reply #8 on: November 06, 2017, 02:05:03 pm »
Money saved? 
Grow a beard

Offline Pir8

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Re: DIY air filter, what have I started?
« Reply #9 on: November 06, 2017, 04:35:26 pm »
am i the only one who can't see any photos from the OP?
It's tapatalk.  Post on their blog... cuz they suck.

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Offline FWR132

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Re: DIY air filter, what have I started?
« Reply #10 on: November 06, 2017, 06:15:19 pm »
Whoa. that is really nice
Regards as always

Offline BibleGeeek

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Re: DIY air filter, what have I started?
« Reply #11 on: November 07, 2017, 10:14:29 am »
dude - paint the heat shields copper and that will look incredible. 
Real men love Jesus and walk with Him.

Offline frankp07

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Re: DIY air filter, what have I started?
« Reply #12 on: November 07, 2017, 05:23:27 pm »
Looks great mate! You'll have to post some pics once you're done painting the rest of it.

Sounds like you might have an Australia market for aftermarket intakes!

Offline dharmic

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Re: DIY air filter, what have I started?
« Reply #13 on: November 16, 2017, 08:20:40 pm »
So a bit later on, and I've hit some more bits with copper. Yamaha's sub-micrometer-thick chintzy chromework has bitten me on this bike with rust spots on the headlight bezel, fork stanchions and rear shocks. So I painted the bezels for the headlight and speedo, as well as the 'chrome' plastic bezel on the tail/stop light assembly.

They look good on their own but there ain't enough to carry a theme on the bike, so they stick out like pimples on a bald man's head.

I'll probably spray a couple of engine covers next oil change when I have to drain it anyway, and see if that carries it.

Heat shields will probably go with the exhaust (after market, two brothers I think) and just replace with copper sheet because the paint isn't high temp stuff.

When the corrosion on the stanchions gets bad enough I'll pull them and look at replacements with gaiters and the tops painted copper (or copper plated) too. We'll see how it goes.

Savings? As usual with this kinda project. $10usd for the air filter vs whatever a stock yammie one is, vs about $2000 of time I should have been working (and billing) instead of stuffing around with this. My sanity and insatiable need to tinker have been appeased though, so I consider the scales in balance overall!

Offline dharmic

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Re: DIY air filter, what have I started?
« Reply #14 on: December 28, 2017, 06:40:00 pm »
And for Christmas my Bolt got itself a new seat in keeping with the rest of it. In my continuing theme of tightwad there was no way I was dropping a thousand bucks on the Yamaha OEM one. So got a cheap and cheerful eBay special for about a tenth of that. The front hinge that came with it had crazy amounts of play (the 8mm pin sitting in a 10mm bore!) so I turned up a Delrin sleeve for it, slop gone. The seat came with Harley type mounts so I had to make some brackets to get it to fit the bike.

I like the look but anyone complaining about how uncomfortable the stock seat is needs to go for an hour's ride on one of these. You'll never think of the stock seat the same again.

If I'm going to keep going with the springer style, I suspect there will be some re-upholstering in the none too distant future. Re-upholstering over some actual padding. Coz at the moment it's negligible :)