I had been wanting to remove the air box and add pod filters too my 2004 Speedmaster for sometime. I just finished it up this weekend. I removed the air box without damaging it, added K&N pods, rejetted the carbs, (put in 150 mains) and designed my own battery box. Took me 3 or 4 weeks, would have been much quicker if my garage was heated!
I had originally planned to buy the battery relocation bracket from the guy on here that sells them, but I got to thinking, I am a mechanical engineer that designs conveyors and special automation. Probably 90% of what I do is design brackets to attach something to something else, so basically, I am a professional bracket designer! And I have access to Solidworks, steel, a laser, a CNC press brake, welders, and a powdercoating booth.
So I designed my own from 14ga (0.075") mild steel. (Future version will have the back plate from 12ga (0.105") to give it a little more strength)
And a carb brace. (This is revised from the actual one so that it can be hooked over the aluminum rod on the carbs without having to take it off)
Parts before installation. (Note some of the bends have cutouts on the bend line to allow it to be hand broke. We did this because the brake operator was having a hard time getting all the bends right and I didn't want to take the time to tweak it in)
After installation. (Future versions will have slots in the two mounting holes to allow you to offset the battery box about 5mm to the right so that you have a little more room for the wires coming out of the fuse box, and I will probably drop it down probably 8-10mm to give more room for wires on top of the battery.
The only part of the original bracket that was used was the part that mounts the fuse box and the key. I cut a piece of 1/8" rubber to fit in the bottom of the bracket for the battery to sit on.
And the completed project. I also added progressive rear shocks, new rear turn signals, and a crankcase breather. It runs great and seems to have more power.
If there is any interest, I could make some for sale. I could do the completed bracket, welded and powder coated black with 1/8" rubber for the bottom, and the carb brace for $100 plus shipping. You can keep your old bracket.
PM me if anyone is interested.
