DIY air intake (flapper removal)

10742 Views 14 Replies 11 Participants Last post by gerbolex, Apr 2, 2014

k9387

Discussion Starter · Apr 15, 2009 (Edited)

£££ for HRC intake? ££ for copies? Nah...

And I know I could have gutted the original but wanted something a little neater and to maximise airflow.

Total cost about £10 and a few hours.

1) Construct ends out of plastic:

2) Construct mould:

3) Cover in fiberglass:

Yeah, had never used this stuff before, should probably have had a practice first. Used about twice as much as I needed too, very strong now though.

4) Test fitting:

And the rest lines up and fits too.

4) Fill and sand:

Has been painted and currently drying, final fitting tomorrow hopefully.

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k9387

Discussion Starter · #2 · Apr 15, 2009

Comparison:

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LDH

· #3 · Apr 15, 2009

wow, looks like a lot of work...

Munki

· #4 · Apr 15, 2009

sure does, but not that bad of a job. Nice DIY

Decreasing Dave

· #5 · Apr 16, 2009

Why can't you just dremel the guts out of the stock one??

I haven't looked at this mod except for your pics but I would think that cleaning out the stock intake wouldn't be as smooth as yours but could be done with a lot less work.

Your thoughts??

Dave

stratsrr

· #6 · May 2, 2009

Mold

How did you mold around the stock one?And then remove it?I wound like to do this.Very cool.

Uin2it

· #7 · May 4, 2009

isn't there a way to just disconnect it vs fullly removing it!? I saw on the Hooligan Tech site how it's done on the 05....is it the same on the 06?

CNI Dawg

· #8 · May 4, 2009

Nice job !
Gonna flow a lot more air than a gutted stock unit.
The next one will be easier

Better than spending $540 for one of these HRC carbon models

http://www.oppracing.com/show_product/120-airduct-hrc-cbr1000rr-2004-2007/

k9387

Discussion Starter · #9 · May 4, 2009

Forgot about updating this, some finished pics:

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k9387

Discussion Starter · #10 · May 4, 2009

Decreasing Dave said:
Why can't you just dremel the guts out of the stock one??

I haven't looked at this mod except for your pics but I would think that cleaning out the stock intake wouldn't be as smooth as yours but could be done with a lot less work.

Your thoughts??

Dave

As I mentioned in my first post I know I could have done this but it wouldn't have been as clean or quite as much air flow. Also had a bit of time on my hands.

k9387

Discussion Starter · #11 · May 4, 2009

stratsrr said:
How did you mold around the stock one?And then remove it?I wound like to do this.Very cool.

I didn't, the ends were made out of sheet plastic and the center was made by creating the shape I wanted between the two ends out of polystyrene, covering with duck tape, vaseline and finally fibreglass. It was all aligned by eye and holding mine up to the original, was gonna make a jig but since this was a one off I decided it wasn't worth it.

Uin2it said:
isn't there a way to just disconnect it vs fullly removing it!? I saw on the Hooligan Tech site how it's done on the 05....is it the same on the 06?

Yeah, you don't need to replace the intake, or even remove the flapper componants, just disconnect and plug the hose under the fairing.

CNI Dawg said:
Nice job !
Gonna flow a lot more air than a gutted stock unit.
The next one will be easier

Better than spending $540 for one of these HRC carbon models
http://www.oppracing.com/show_product/120-airduct-hrc-cbr1000rr-2004-2007/

Yeah, seeing those is what gave me the idea to make my own. Mine might not be as smooth or as light but it ain't far off and is much cheaper.

There is a bloke in Aus (I think) that makes CF ones a lot cheaper, doesn't make all that many of them though (last time was a good few months ago).

blade fighter

· #12 · Oct 19, 2009

k9387 said:
I didn't, the ends were made out of sheet plastic and the center was made by creating the shape I wanted between the two ends out of polystyrene, covering with duck tape, vaseline and finally fibreglass. It was all aligned by eye and holding mine up to the original, was gonna make a jig but since this was a one off I decided it wasn't worth it.

Yeah, you don't need to replace the intake, or even remove the flapper componants, just disconnect and plug the hose under the fairing.

Yeah, seeing those is what gave me the idea to make my own. Mine might not be as smooth or as light but it ain't far off and is much cheaper.

There is a bloke in Aus (I think) that makes CF ones a lot cheaper, doesn't make all that many of them though (last time was a good few months ago).

Anyone know of thios bloke from Oz??
I would be very interested in speaking with said bloke

atomicps

· #13 · Oct 19, 2009

looks good to me

bobneal08

· #14 · Oct 19, 2009

Nice job... But a lot of work ...

gerbolex

· #15 · Apr 2, 2014

Hello k9387 !!!

k9387 said:
I didn't, the ends were made out of sheet plastic and the center was made by creating the shape I wanted between the two ends out of polystyrene, covering with duck tape, vaseline and finally fibreglass. It was all aligned by eye and holding mine up to the original, was gonna make a jig but since this was a one off I decided it wasn't worth it.

Yeah, you don't need to replace the intake, or even remove the flapper componants, just disconnect and plug the hose under the fairing.

Yeah, seeing those is what gave me the idea to make my own. Mine might not be as smooth or as light but it ain't far off and is much cheaper.

There is a bloke in Aus (I think) that makes CF ones a lot cheaper, doesn't make all that many of them though (last time was a good few months ago).

Hello K9387
I'm a french Guy....

I'm looking for a map (PC5 or PC3), for SC57 with a same configuration of you.
Could you send me your map please :
My email : [email protected]

Thank you in advance.....

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