HOW TO:build a hybrid yzf/fzr airbox without cutting it up
Posted: Thu Apr 02, 2009 9:51 am
In this write-up, Im going to explain how I combined the fzr and yzf airbox so it will fit under the yzf tank without cutting the airbox.
first off, you will only need the bottom of the fzr stock airbox, and the top of the yzf 95-96 airbox. Im not sure if the later model yzf airbox tops will work, I've never even seen one, but if there the same, it should work
.first of all , you need to get a good piece aluminum or plastic pretty thick (1/4) or plexi glass would even be better, since you can see the holes through it when it comes time to drill them out.
I used a 12" x 18" cuttting board i happened to find at lowes for around 8 dollars(ok, I wont lie,Its my old ladies cutting board, just dont tell her). I traced the outline of the yzf top outfirst, using a common edge for both pieces top and bottom.I next place the fzr bottom on the same leading edge( use the rear of each airbox toward the rear of the bike), and trace it out.
You next want to cut out the patttern only on the outside edges, this way when you combine the two, both pieces are sealed. when you get the pattern cut out
All you have to do is get a long punch or nail or even a screw driver and mark the holes to be drilled out. you want to mount the yzf top to the plate permanant ( you can still remove if if you have toand seal it with a homemade rubber cutout gasket, or you can just run a bead of rtv sealant around the edge. you have to go to the hardware store and buy some wood screws that have a flat top or countersink the stock screws when mounting the top, because when the fzr bottom is screwed to the plate , some of the screw heads from the yzf top keep it from sitting flush.
next mark the holes for the fzr bottom and drill them out . these will have to be mounted with screws and nuts, or i just happenned to have a nutsert tool , so I installed nutserts on them. you can also use tee nuts or propel nuts, one of those threaded sleeves from lowes( the thing that looks like a washer on top and a sleeve connected to it that is threaded so it doesnt pull through the hole
Next thing is just to drill out some large holes for the air to flow through each piece creating a freeflowing one piece airbox. just be carefull not to cut too much material away so the piece stays rigid and doesant get to flimsy and week. you also have to cut out the large hole for the yzf air filter to fit through,and you may want to go buy some weather striping tape( foam tape) or place a thick piece of foam on the bottom of the air filter or the fzr lower box because the air filter sits just a little bit off the bottom and its suppose to sit flush.
I have already mounted this under my yzf tank and it fits perfectly without any clearance problems and this way you dont have to hack up an airbox and have to worry about it leaking all the time
tee nuts and propel nuts
first off, you will only need the bottom of the fzr stock airbox, and the top of the yzf 95-96 airbox. Im not sure if the later model yzf airbox tops will work, I've never even seen one, but if there the same, it should work
.first of all , you need to get a good piece aluminum or plastic pretty thick (1/4) or plexi glass would even be better, since you can see the holes through it when it comes time to drill them out.
I used a 12" x 18" cuttting board i happened to find at lowes for around 8 dollars(ok, I wont lie,Its my old ladies cutting board, just dont tell her). I traced the outline of the yzf top outfirst, using a common edge for both pieces top and bottom.I next place the fzr bottom on the same leading edge( use the rear of each airbox toward the rear of the bike), and trace it out.
You next want to cut out the patttern only on the outside edges, this way when you combine the two, both pieces are sealed. when you get the pattern cut out
All you have to do is get a long punch or nail or even a screw driver and mark the holes to be drilled out. you want to mount the yzf top to the plate permanant ( you can still remove if if you have toand seal it with a homemade rubber cutout gasket, or you can just run a bead of rtv sealant around the edge. you have to go to the hardware store and buy some wood screws that have a flat top or countersink the stock screws when mounting the top, because when the fzr bottom is screwed to the plate , some of the screw heads from the yzf top keep it from sitting flush.
next mark the holes for the fzr bottom and drill them out . these will have to be mounted with screws and nuts, or i just happenned to have a nutsert tool , so I installed nutserts on them. you can also use tee nuts or propel nuts, one of those threaded sleeves from lowes( the thing that looks like a washer on top and a sleeve connected to it that is threaded so it doesnt pull through the hole
Next thing is just to drill out some large holes for the air to flow through each piece creating a freeflowing one piece airbox. just be carefull not to cut too much material away so the piece stays rigid and doesant get to flimsy and week. you also have to cut out the large hole for the yzf air filter to fit through,and you may want to go buy some weather striping tape( foam tape) or place a thick piece of foam on the bottom of the air filter or the fzr lower box because the air filter sits just a little bit off the bottom and its suppose to sit flush.
I have already mounted this under my yzf tank and it fits perfectly without any clearance problems and this way you dont have to hack up an airbox and have to worry about it leaking all the time
tee nuts and propel nuts
, but if you have half a yzf airbox lying around along with a cutting board then your good to go!
..i'm probably just going to grind down the YZF600 one i have so it fits under my tank. I need it on my YZF carbs, i still have to figure that part out.