CF Airbox

[Bitza]

Have been working on this one for a while using a 2003 OEC airbox as the basis for the mould making. Coil studs & spacers substituted with a pair of turrets moulded in. The upper and lower sections made separately and bonded together later, the two inner trumpets are 3d printed epoxy based material. The top section with the filter seat is very tricky to make and I used chopped toe for that. The main box is quite a complex too, especially with the coil turrets and the two outlet flanges.
The finish is very poor so I got out the rattle can, but functionaly OK I think?!
Compared to my previous set up I saved 325gms. But worth pointing out that the lids are very heavy. I only use the bottom edge/rim saving over 600gms.

 

[Mr Gazza]

I like that a lot and have to congratulate you for even taking on such a challenge in the first place, let alone getting a good result like that.

I replaced the pins that hold the lid clips on mine, with stainless roll pins, but a little bit of Ti, alloy or carbon rod might save a few grams?
I know the lids are heavy and if you're going to cut them down they work out as properly wasted weight as it's only the retention of the filter that they are doing.
I had an idea for that using double glazing spacer bar which is basically a very thin alloy box section, available in various sizes if you can persuade a double glazed unit maker to sell you a length from their stock.
You might also be able to persuade them to bung you a handful of the plastic corner connectors of the right size for the bar, so you can make a square frame of the right size to fit the filter.
I suspect you would need to also make some bespoke clips to retain the very low and light frame, using the original method.
The box section would easily deform into little detents for the clips with a suitably made drift/punch. (Or a screwdriver!)
Food for thought? It would weigh about 4 fifths of FA..

 

[Mr Gazza]

I must have posted this idea before, because I have a picture of some 6 x 6mm spacer bar.





It comes in bigger sizes, I think in 2mm increments but becomes unequal box with the perforated and opposite formed sides growing. with the other 2 side staying at 6mm.

 

[Bitza]

I simply fix the filter in place, with the rim of the original lid(50gms) loops of inner tube and CF pins. Have tried to better the lid bit but 50gms is hard to beat.

 

[Darren69]

Congrats on the airbox. I can see that took many hours. There is a company that makes the cut down lids from carbon fibre but they are about £200 but retain the standard oem clips.

 

[Bitza]

Well Darren, you have to laugh they go to all the trouble to make a lightweight revised filter retainer but keep the the heavy bits.... the steel spring clips, not all the custom whizz bits a what they claim to be I guess.

 

[Darren69]

Yea, I know I did consider one but couldn't really justify it since you can't see it, weight saving is negligable and there's really no real benefit. The whole box would havè to be replaced ideally.

Carbon open cover for Ducati Monster air filter.

Open air filter cover in first-rate carbon for Monster. Replica of the Ducati Performance open cover but with the best carbon and finishes. Sku : C4USC4US223.1

www.carbon4us.com

they don't give a price for the whole one but I expect its probably close to 4 figures. Maybe if I fit my carbon tank that would be the next step?

Oversized full carbon airbox for Ducati Monster

Airbox maggiorato in full carbon per Ducati Monster - Giordano Loi Sculture Dinamiche

www.giordanoloi.it

 

[Mr Gazza]

Out of curiosity I just weighed 4 @ 440mm lengths of 6 x 12mm spacer bar and it came to 40 grams. I reckon you'd only need about half that much to make a square frame to hold down with your bands.. Should have weighed some model wing bands as well. Doh!

 

[Darren69]

It's a packet of crisps!

 

[Bitza]

Have gone minimal, had a new look at it and with the straps plus the deap filter seat, I don't really see why it requires anything but have gone overboard with a pvc frame to give a bit of stiffness. At 18gms it's a bargain.