this is a full write up of start to finish of my airbox i built for my wolverine.





here's some more pics of the airbox. i did some welding after work today on it. it only needs the front and the top to finish it off. but heres what i have so far.





the little peice of pipe is going to be the airbox drain.





here's a close up of my welds.





more pics. the filter showed up friday.





i just set it in the box with the front piece. the little piece of pipe stuck in the front is for the crank case breather.





this is going to be the front of the airbox. this will put my welding skills to the test. the pipe is a .065 wall thickness which is a little over 1/16 of an inch. and i'm welding it to a 1/8th thick peice of aluminum. and i have to not burn through the pipe at all. but anyway heres the pics of what i got.





i got the pipe welded into the front plate. my dumbass forgot the crank case breather tube and the rest of the box to finish welding that stuff up though. but anyway here are the pics.







here's a pic of my welds. they aren't that great looking but i didn't burn into the inside of the pipe at all which is what i was hoping to avoid. so that is all good.



ok i have the front plate welded on. i welded all the way around the inside of the box. and tonight i cut the mounting brackets and mearsured for the top. if all goes well i will have it done friday after work. and the wolvy will be really to go VROOM VROOM!!!

here's the new pics.

the welds inside. i don't really like the looks of them. i couldn't really get my TIG torch steady because i could only hold on to the very end of it, to get far enough into the box. then i had to add filler rod the same way. but it's all welded up so it should drain out water and other crap good now with nothing to stop it up on the sides.



the filter on the front plate.



and the top which i changed my original plan of running half way front to back to running half way side to side. it still needs cut.









FINISHED!!!!!! (basically. lol. it just needs 4 holes drilled for the lid mounts.)

here's the basically finished product.

this is the lid that still needs the 4 holes drilled. but you can see the whole box here. other than my fat hand in the way. lol


more pics here.

this is my tiny little weld to help hold the air filter on. (if anyone tells you a TIG welded isn't accurate(sp), smack them in the face and show them this picture)


my little welds around the front to help hold the carb boot on.




and here's my gusset for the longer of the 2 mounts.


another pic of it.


and the underside of that long mount.


here's the shorter mount.


and another shot of it.


here's the front of the box all buffed of up nice.


here's a shot of the underside of the lid.



ok here is the last update. the lid is still not on it yet but you guys get the idea with that. so here is my custom airbox installed.

it fit like a glove.







from the side.



and here's the old airbox. (cough i like mine better cough cough)







my review of my airbox. looks good, fit good, deffenately make more power. the wolvy is alittle more cold blooded then when it was stock but after it warms up it's got more power for sure. i can actually ride out a wheelie with it. i was doing power slids around corners on the street (out in the country of course) and apparently this thing has a speed limiter at 55 MPH. i got it up to a top speed of 56 MPH and i could hear the engine was coughing and sputtering. but all in all i think this was a great inprovement over stock.

 

Very nice good work welds look great far better then I can do.

 

nice job on the welding. i have a tig and have a hard time getting into the corners you must do a little tiny bit of welding huh.

 

thanks for the comments guys.


yeah i am a TIG welder at a company called Baltimore Aircoil Company. i build air coil units. so yeah you could say i do a little bit of welding. lol.


thanks again for the comments guys

 

Sad that has to go into a quad... Very nice Work!! Sweet Welds for sure!!

Did you use 6061? or 5052 AL ?

I love having a sheet metal shop available to me... I don't even need to do the work... just bring them a bring and the AL and wham -- sometimes as quick as 2 weeks or as long as 2 months my skid plates are bent up [img]i/expressions/face-icon-small-smile.gif[/img]

-Steve

 

WOW

these welds look amezing, good job

 

<div class="FTQUOTE"><begin quote>Originally posted by: CraZySteve

Sad that has to go into a quad... Very nice Work!! Sweet Welds for sure!!



Did you use 6061? or 5052 AL ?



I love having a sheet metal shop available to me... I don't even need to do the work... just bring them a bring and the AL and wham -- sometimes as quick as 2 weeks or as long as 2 months my skid plates are bent up [IMG][/IMG]

-Steve</end quote></div>


why's it sad it's going into a quad? i'm just curious. and i'm not sure what the king of aluminum it's is. i would like to assume that it is 6061 because that is what every other kind of aluminum in our shop is.


and thanks again for the comments.

 

2 words. holy ****. what would you charge to build one for my 99 yamaha big bear? lol =)

 

Very nice, I have a 115 wire mig but wish like hell I had an aluminum weld setup, looks really good, nothing like a nice puddly smooth aluminum weld. Great Job!

 

<div class="FTQUOTE"><begin quote>Originally posted by: cadillacdude1975

2 words. holy ****. what would you charge to build one for my 99 yamaha big bear? lol =)</end quote></div>

sorry after building this one i wouldn't want to try another one. this one was alot of fit and cut and fit and cut again.


<div class="FTQUOTE"><begin quote>Originally posted by: ROBBASS

Very nice, I have a 115 wire mig but wish like hell I had an aluminum weld setup, looks really good, nothing like a nice puddly smooth aluminum weld. Great Job!</end quote></div>


yeah i absolutly love welding aluminum.