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techtalk:ref:carb06a [2019/09/15 16:53] – created hippysmacktechtalk:ref:carb06a [2024/01/11 23:26] (current) – [Homemade Round Air Cleaner Assembly] hippysmack
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 ====== REF: Carburetor, Intake Manifold & Exhaust - Sub-06A ====== ====== REF: Carburetor, Intake Manifold & Exhaust - Sub-06A ======
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-====== Homemade Air Cleaner Assembly ======+====== Homemade Round Air Cleaner Assembly ====== 
 +Article by hallin222 of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/83614-homemade-a-c-how-to-w-pics?t=626891)) \\
  
 +A K&N filter is used with everything else being fabbed. \\
 +An 1/8" aluminum plate was used for the material. \\
  
 +{{:techtalk:ref:carb:ac_mod_10_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) \\
  
 +Trace the filter onto the aluminum sheet (whichever filter you will be using). \\
 +Cut the piece with a jigsaw (best). \\
 +Other cutting tools work also but the rotary blades create more heat and will melt the edges. \\
 +In that case, cut outside the edges so you can sand back to the lines you made. \\
 +Drill the holes for the carb mount and smooth all the edges. \\
 +
 +{{:techtalk:ref:carb:ac_mod_8_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) {{:techtalk:ref:carb:ac_mod_7_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) {{:techtalk:ref:carb:ac_mod_6_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) \\
 +
 +Drill two holes in the plate for dowels (spacers) for the front cover (also created from tracing the filter). \\
 +Cut a mounting bracket (this one is 1/4" thick) to mount across the dowels and tap the bracket for the size mounting bolts you choose. \\
 +Align the outside cover on the assembly and drill a center mounting hole through it. \\
 +You can then buy a long drill bit to assist in lining the center hole to the cross brace in the back. \\
 +Then tap that hole for the size bolt you choose. \\
 +
 +{{:techtalk:ref:carb:ac_mod_5_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) {{:techtalk:ref:carb:ac_mod_4_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) {{:techtalk:ref:carb:ac_mod_2_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) \\
 +
 +Make sure you test fit along the way as it's being built. The bolts and spacers here made contact with the carb bracket. \\
 +It was later fixed with shorter counter-sunk bolts to sit flush with the back face to allow proper gasket sealing.
 +You can leave the finish as it is, polish it, paint it or have it chromed. \\
 +Either way it'll be one of a kind. \\
 +
 +{{:techtalk:ref:carb:ac_mod_1_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) {{:techtalk:ref:carb:ac_mod_11_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) {{:techtalk:ref:carb:ac_mod_9_by_hallin222.jpg?direct&300|}} ((pic by hallin222 of the XLFORUM)) \\
  
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Trace: • REF: Engine Mechanicals - Sub-01I • REF: Engine Mechanicals - Sub-01M • EVO: Engine Control - Sub-03b • REF: Tools - 162