Making a custom airbox

[tritonwow]

Hey all! Well my 95 D12 engine is in bits and I'm not near it to work on it. BUT I was able to fit the airbox in my luggage and thought I would post where I'm at.
My goal was to make a male mold which has the stock inner volume. I can then form fiberglass or carbon fiber around it.
I had a couple of false starts with blocks of foam and Plaster of Paris (POP) and ended up using preimpregnated POP cloth (Rigid Wrap). The intake side of the airbox is solid with POP and I'll hav to get it out and start again.


The engine side turned out much better and I'll have to finish it up and will most likley fill it with POP once the outer shell is complete. Once at that point I'll use self hardening clay to form the "sealing lip".




I had planned on vaccumn (sic) forming the CF but I don't think I'll have enough time so I plan to make a rubber female mold before I fly. Once at home I can remake the male mold with poured acrylic (hopefully so I can make more!) I'll probably try a hand formed layer just to see how it turns out.
I believe I'll be able to cut both three and four cylinder holes because of the indexing marks on the original box. Also, I plan to make the intake side in two pieces for ease of removal. This should be a stock replacement using all other stock bits (however I might make it to fit the KN airfilter).
A question to the masses: How tight are the connecting rubbers at the intake side? I ask because the thickness of the stock plastic is 3/8" or so and I believe the CF will be much thinner. If the rubbers are not tight I'll have to build up the new box on that end.

[Roden]

I can't answer your question on the rubbers, sorry mate but my question to you is: do you plan on making these in numbers once developed?

I reckon they will sell like the proverbial hot cakes!

Cheers,

Roden

[tritonwow]

I know many our brothern on this wonderful site are looking for a replacement airbox. I also wanted to contribute what I can back to our community but I don't have alot of time. I was thinking if I get the mold done maybe I can farm out the work for a group buy.
If it works out I might also make molds of the other parts of the intake (can't remember the name of them; resonators or whatever).
Of course I wan't to make sure they fit, are functional, and won't disinegrate on someone.
Bottom line is I have you guys in mind. This won't be a one-off if anyone else here has an interest.

PS I have some ideas for an airbox around the four independent KN filters but I need to make some measurements.

[Roden]

Thanks bro, you have my interest and probably every other person who has had the dubious pleasure of carrying out a simple air cleaner change!

Cheers,

Roden

[Fridgehq]

Yea I agree 100%

[Ozbernie]

Make them........
make them well..........
and they will sell
Put me down for one if it happens

[tritonwow]

Ok, I know its been months and the airbox was on the back burner BUT I've still been mulling it in my mind. One of the big issues I'm having making this in my garage is the attaching hardware for the two pieces. I've thought of several ideas; threaded post with a wingnut, plain jane nut and bolt, screws, latch, spring clips, dzus fasteners, etc. I think one of the easiest to make/use to separate the halves would be hooks and high grade/industrial rubber bands.


more pics in the albumn

The issue is it looks a bit tacky (not for me really but others maybe). Its a rough photo to get the idea where the clips would be. One would then stretch the bands accros the intake side to attach on the opposite side of the engine piece of the airbox. Confused?

Anyhow, I'm up for ideas on attachment hardware as I'm working the remaining bondo/smoothing of the mold. I have all the materials to attempt the prototype soon.

Funny thing is I put FCRs on the D12 and don't have the airbox anymore!