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Old 02-05-2013, 05:26 AM   #1
cat OP
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How to make neat holes in airbox?

How to make neat holes in airbox?
Can i use a hole punch or would it crack the plastic?
A sheet metal punch, the kind that you drill a pilot hole and then tighten the tool and...?
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Old 02-05-2013, 05:27 AM   #2
eddie bolted
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Hole saw.!
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Old 02-05-2013, 05:34 AM   #3
LuciferMutt
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Why are you putting holes in the airbox?
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Old 02-05-2013, 06:19 AM   #4
It'sNotTheBike
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Quote:
Originally Posted by LuciferMutt View Post


Why are you putting holes in the airbox?

Probably because the OP imagines the trained engineers who designed the air intake
botched the job, though those engineers had access to a dyno and more than likely spent
many hours making sure the airflow was optimized for the resonant cavity of the air box,
( think of Helmholtz and you will be on the right track).


How likely is it that the engineers did a bad job and someone who needs to ask how
best to cut holes in the air box will do a better job ? Sort of like leaving an orangutang
in front of a typewriter and waiting for the sonnets of Shakespeare to be produced
( don't hold your breath waiting for anything intelligible to come out of that typewriter ).




.

It'sNotTheBike screwed with this post 02-05-2013 at 06:26 AM
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Old 02-05-2013, 06:25 AM   #5
Wlfman
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1in putty knife. Heat the blade and it melts right thru the plastic making nice straight lines.
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Old 02-05-2013, 06:28 AM   #6
It'sNotTheBike
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Originally Posted by Wlfman View Post
1in putty knife. Heat the blade and it melts right thru the plastic making nice straight lines.


You shade tree wannabe "tuners" will have that air box working "right" in no time ... LOL !!!
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Old 02-05-2013, 06:39 AM   #7
groundrules
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Quote:
Originally Posted by It'sNotTheBike View Post
Probably because the OP imagines the trained engineers who designed the air intake
botched the job, though those engineers had access to a dyno and more than likely spent
many hours making sure the airflow was optimized for the resonant cavity of the air box,
( think of Helmholtz and you will be on the right track).


How likely is it that the engineers did a bad job and someone who needs to ask how
best to cut holes in the air box will do a better job ? Sort of like leaving an orangutang
in front of a typewriter and waiting for the sonnets of Shakespeare to be produced
( don't hold your breath waiting for anything intelligible to come out of that typewriter ).
you don't sound as smart as you think you sound.
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Old 02-17-2013, 10:53 AM   #8
DirtyBlackIrish
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Quote:
Originally Posted by groundrules View Post
you don't sound as smart as you think you sound.
I second that!
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Old 02-05-2013, 06:58 AM   #9
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Quote:
Originally Posted by It'sNotTheBike View Post
Probably because the OP imagines the trained engineers who designed the air intake
botched the job, though those engineers had access to a dyno and more than likely spent
many hours making sure the airflow was optimized for the resonant cavity of the air box,
( think of Helmholtz and you will be on the right track).


How likely is it that the engineers did a bad job and someone who needs to ask how
best to cut holes in the air box will do a better job ? Sort of like leaving an orangutang
in front of a typewriter and waiting for the sonnets of Shakespeare to be produced
( don't hold your breath waiting for anything intelligible to come out of that typewriter ).




.
Your right,it seems like a great idea to swiss cheese your airbox,till that first real dusty ride and the filter plugs or passes dirt. Or you just cant quite get the jetting right no matter how much you mess with it,or the new noise produced makes you crazy.
Its fun to second guess engineers though.
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Old 02-07-2013, 06:17 PM   #10
Range Motorsport
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Quote:
Originally Posted by It'sNotTheBike View Post
Probably because the OP imagines the trained engineers who designed the air intake
botched the job, though those engineers had access to a dyno and more than likely spent
many hours making sure the airflow was optimized for the resonant cavity of the air box,
( think of Helmholtz and you will be on the right track).


How likely is it that the engineers did a bad job and someone who needs to ask how
best to cut holes in the air box will do a better job ? Sort of like leaving an orangutang
in front of a typewriter and waiting for the sonnets of Shakespeare to be produced
( don't hold your breath waiting for anything intelligible to come out of that typewriter ).




.
You are right no one has ever removed or modified or redesigned an airbox and made more power...

Just like exhausts, fuel maps, and head porting do nothing for performance. You can also take any bike off the showroom and race it because they engineered it to be the fastest most efficient bike from the factory.
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Old 02-07-2013, 06:42 PM   #11
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Can't hurt to try

On my F800 I used a hole saw to put 3 holes on the part of the air box that's above the filter. I think the holes are 1" maybe 1 1/4" Before I did this I thought about what would happen if i wasn't happy with it. The plastic part I drilled into cost lass than $10. A BMW part that's only $10??? I figured it was worth 10 bucks to see if the mod that had worked on everything else I'd ever owned would work on this. I noticed better bottom end/low speed response and no negative results(same top end, mileage etc.) I do hear a little more engine noise but it's nothing.
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Old 02-07-2013, 07:06 PM   #12
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Quote:
Originally Posted by It'sNotTheBike View Post
Probably because the OP imagines the trained engineers who designed the air intake
botched the job, though those engineers had access to a dyno and more than likely spent
many hours making sure the airflow was optimized for the resonant cavity of the air box,
( think of Helmholtz and you will be on the right track).


How likely is it that the engineers did a bad job and someone who needs to ask how
best to cut holes in the air box will do a better job ? Sort of like leaving an orangutang
in front of a typewriter and waiting for the sonnets of Shakespeare to be produced
( don't hold your breath waiting for anything intelligible to come out of that typewriter ).
.
The goals of the engineers might differ from the goal of the OP. It is possible to tune the same engine differently to get different characteristics. I'm not saying going around drilling random holes in things is the way to go, but if you can manage to shove more air and fuel into an engine in the correct mixture, you will get a bigger boom and more power. Whether or not this produces undesired results by way of reduction of fuel economy, airbox noise, etc... is irrelevant; none of those things are (hopefully) the goal of the OP.

On the dyno comment, you do realize that the reason most people cut holes in their airbox is that they've purchased a jetting kit which requires larger airbox holes work properly? Most companies who make these kits such Dynojet or JD, also have access to dynos, and their results against the stock power curves can be seen.

Anyway, to answer the OP's original question, use a holesaw to cut out the corners then use a heated razor blade to cut nice straight lines between the holes. Optional is some sort of sanding wheel for cleanup after. You can see it illustrated here on a DRZ400S https://www.youtube.com/watch?v=VtKWbs0N5lo
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Old 02-08-2013, 06:49 AM   #13
kantuckid
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Quote:
Originally Posted by It'sNotTheBike View Post
Probably because the OP imagines the trained engineers who designed the air intake
botched the job, though those engineers had access to a dyno and more than likely spent
many hours making sure the airflow was optimized for the resonant cavity of the air box,
( think of Helmholtz and you will be on the right track).


How likely is it that the engineers did a bad job and someone who needs to ask how
best to cut holes in the air box will do a better job ? Sort of like leaving an orangutang
in front of a typewriter and waiting for the sonnets of Shakespeare to be produced
( don't hold your breath waiting for anything intelligible to come out of that typewriter




.

Are you a hotrodder by chance?
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Old 02-05-2013, 07:41 AM   #14
groundrules
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you guys really think every bike shipped from the factory is tuned for maximum performance, or do you think the engineers in question might have had to consider factors like fuel economy or emissions standards or rider-friendly power delivery, or a hundred other factors? I've owned two bikes where airbox mods were a well-documented and much-utilized improvement. It happens.

now, back to the original question: step drill for small holes.
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Old 02-05-2013, 08:10 AM   #15
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Quote:
Originally Posted by groundrules View Post
you guys really think every bike shipped from the factory is tuned for maximum performance, or do you think the engineers in question might have had to consider factors like fuel economy or emissions standards or rider-friendly power delivery, or a hundred other factors? I've owned two bikes where airbox mods were a well-documented and much-utilized improvement. It happens.

now, back to the original question: step drill for small holes.
CORRECT!

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