I have made quite a few changes to my bike (05 america) one of them being fitting K&N pods, I decided I wanted to keep the battery where it is, and instead of removing the air box I decided to convert it too a tool box.
hopefully the following pics will show you how I did the conversion.
firstly I removed the air box and cut off the two tubes that used to connect to the carbs.
[image]http://http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0466.jpg?t=1297342205[/image]
after removing the top, I made up a steel plate to fit inside the air box, this plate becomes the fourth wall of the tool box,
[image]http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0468.jpg?t=1297342205[/image]
after refitting the top I made up two blanking plates to close up the holes at the front of the air box, these were glued with araldite (epoxy resin)
[image]http://http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0471.jpg?t=1297342205[/image]
I fitted a bracket to the front top of the now tool box to give suport, after drilling and tapping a hole in the frame.
you can also see in this pic that I have fitted a steel plate over what used to be the air inlet hole, ( again stuck with resin) and this now becomes the lid to the tool box.
[image]http://http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0478.jpg?t=1297342205[/image]
I then painted the whole thing with matt black and fitted it to the bike, you can see in the next pics that I have done away with the cheese graters and some modification is needed to the left side panel that sits over the battery, I hope the pic is self explanetary as to what I did to it.
[image]http://http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0506.jpg?t=1297342205[/image]
here is the view from the right side.
[image]http://http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0503.jpg?t=1297342205[/image]
and a couple of more pics to show how the bike looks.
[image]http://http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0514.jpg?t=1297342205[/image]
[image]http://http://i794.photobucket.com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/th_100_0536.jpg?t=1297342205[/image]
I hope I have explained in enough detail the steps I took to complete the job. the finished tool box is not massive but is big enough for a basic tool kit, and it shows that you dont have to remove the air box in order to fit K&N pods.
since doing this mod I have made up some mid mount foot controls these have transformed the ride for me, no more sore butt on long rides and a much better for getting feed back from the bike.
I will post pics of that mod as soon as I can get the pics together.
