Filtered Air Box Construction – 1.5 hrs

Wednesday Apr 24, 2013

A couple of days ago I cut out a piece of .025 thick alclad sheet to fit into the bottom of the filtered air box fiberglass shell. That is because I have heard of cases where vibration caused the filter to literally rub through the fiberglass. The aluminum sheet just provides a harder surface against which the filter contacts so hopefully, if anything, the filter will wear and not the aluminum. I glued the aluminum sheet into the shell using ProSeal and tonight it was pretty well set up.

The evolution of the filtered air box continued tonight as I fit the top plate to the fiberglass shell. The top plate needs to bend upward near the air inlet so I cut two notches in the side walls and made a slight bend between those two notches so the top plate generally follows the angle of the fiberglass shell.

I flipped the top plate over and drilled four additional holes to attach to the top mount as well as hold the clips that restrain the position of the filter. I cut the raw stock for the clips and match drilled them to the top plate in the positions required to hold the filter just inside the cutout in the top plate. The filter actually sits flush against the top mount.

Here is the quasi-assembled air box with the filter installed.