Bonneville America Forums Forums Technical Forums Custom Corner air box conversion to tool box

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.

I cant see the pictures

I got one of them up for you but as you can see it's just a thumbnail. Any chance you can re-post? Check the Forums help section... there's a pretty good thread in there about posting pictures.

I thought I followed the instructions to post pics, but must have done something wrong, I will try again, any advise appreciated.

You have to upload to a server like photobucket then paste the location in the UBB code for image.

I didn't sort them but there they are.

I have done that

You did everything right except the location, it should look like this. [image] http://i794.photobucket. com/albums/yy222/steve303sg/bike%20pics/air%20box%20mods/100_0466.jpg [/image]

with none of the extra spaces I put in there to show you. Copy the direct link.

thanks for the help, I am much happier using spanners than computers, I hope you guys can get the idea of what I have done, if anyone needs more info please ask, just dont ask me how to post pics.....
thanks

Dang, and here I went and fixed the other thread. I guess I'll just delete that one...

thanks john at least here they are in the right order,

Did you make the bracket for you crankcase filter?

Good work. One thing I would consider is relocating the crank case filter. They have a tendancy to get nasty.

Nice work Steve, doesn't look odd or out of place and utilises the space real well. Good one. I wouldn't be surprised if you're asked for some plans or questions so others can do the same.

I suppose with your winters, the plus side is you've got plenty of time to have your bike off the road. Poor us here in Aus can't afford the time cos we're too busy riding

Good stuff anyway to see new ideas still happening.

Tools? What are ya gonna use THEM for?

They're for when you're riding with a group of Harleys. Make sure your tools are standard, not metric.

yes I made the crankcase breather bracket from sheet stainless.

How much chewing gum and bailing wire to YOU carry for such an occasion?

Very nice, Thats a good clean looking mod. Quality work across the board.