Motorcycle airbox for 2 intakes

I have a Suzuki GS550E 1979 Engine. It has 4 cylinders so 4 carbs for 4 air intakes. 

The single coned air filters bump into the frame so I wanted to make an air filter which would fit and I could personalise. 

I was going to make a 4 box set up but felt this would have been more difficult to fit and maintain. not to mention I would have to print it in sections/halves. 

SO .. I have made a 2 intake option.  This has been measured and checked with a calliper tool and images show it fitted also. 

Some additional Hardware will be required. 5 screw bolts and 5 heat set threaded brass inserts. A drill and drill bit to put your pilot holes or edit the file to place them where you want. Sand paper and paint to your choice. 

The idea is to then place air filter material inside the box pressed against the edges - likely some tack gluing will be required to keep it in place. I will add photos!

The sizing should allow for the airbox to sit side by side with a second so all ports are covered.

The way it works - disassemble the old air filters - you can re use most parts - the rubber fitment piece and the metal plate it connects to slide inside the unit with the rubber part poking through. You will need to glue the metal part to the 3D printed part on the inside of the unit. 

It will poke through enough to use a jubilee clip as usual to hold onto your carbs.

Now you could try using the old metal mesh and filter material - which if your careful enough cutting with tin snips can be done and would save having to buy more filter material and offer additional protection. 

However take great care as it will have sharp edges! The metal could also be heated to melt into the 3D part to keep it in place but this would mean burning the filter material and would require it being separated. Alot of work!

The other option is to tack glue it in place. 

What I have done is cut to fit the foam so the joins are hidden where there are thicker pieces of wall. Superglued spots of the foam along the base so I can tear out if I need to replace the foam for service. 

The box has been uv resin coated - though this was my personal preference as I MAY TRY painting some of it for effect. 

Its not necessary to coat but a lacquer would obviously help protect it and make it more washable friendly!

Have fun  hope someone likes the design.

well I love this design but its quite large so I HAVE MADE A VARIANT which is slimmer by 15mm to clear the bikes where frames get in the way.