How to make neat holes in airbox?

[cat]

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...?

[eddie bolted]

Hole saw.!

[LuciferMutt]

Why are you putting holes in the airbox?

[It'sNotTheBike]

Originally Posted by LuciferMutt

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 ).




.

[Wlfman]

1in putty knife. Heat the blade and it melts right thru the plastic making nice straight lines.

[It'sNotTheBike]

Originally Posted by Wlfman

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 !!!

[groundrules]

Originally Posted by It'sNotTheBike

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.

[Foot dragger]

Originally Posted by It'sNotTheBike

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.

[groundrules]

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.

[kubiak]

i havent tried it yet but try a piece of metal pipe the diameter you need and heat the end and push it through the plastic. maybe try it on a extra part first though.

[Skinner]

Originally Posted by groundrules

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!

It's easy to be a smart ass, it's hard to actually use your brain before just being a dick.

[bomber60015]

Hole saw or step drill, either one . . . . but back up the plastic with something (soft wood, perhaps) or you may create a hole that is larger than you intended . . . . . (depending on the plastic)

[Bronco638]

Originally Posted by cat

Q: How to make neat holes in airbox?

A: A sheet metal punch, the kind that you drill a pilot hole and then tighten the tool.

I have used this method to good effect.

[H96669]

Step drill....they are cheap at harbor freight. I think mine will go to an inch. Anything bigger and out comes the hole saws. But you need backing for the last otherwise you'll tear the plastic.

You can countersink the holes....may help with airflow.

Smaller holes with side access, out comes dad's old airplane tools, namely the sheet metal punch. I think HF has cheap replicas of that tool.

[kruzuki]

And remember to keep the drill speed low so the friction doesn't melt the plastic and ruin your nice, clean edge.