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DIY Air Intakes

jbhotchkiss

Cruisin' Guzzisti
GT di Razza Pura
Joined
Aug 29, 2009
Messages
163
Location
Salem, OR
Convinced I could do better, I removed the K&N pods (dirty, nasty little things) from the throttle bodies on my 1200 Sport and replaced them with filtered velocity stacks. Trial and error led to a solution that I am very happy with. And they look good too! Shame they’re covered up.

The approach was to create a velocity stack for each throttle body, same length as the original (4.5 inches), with adequate filtration without using a pod filter. This was achieved using silicone hose to join a velocity stack to each throttle body, a triple-layer screen on the end of each velocity stack, and a pre-filter over each screen.

Parts used, and their sources are as follows.
  • Aluminum velocity stacks (x2), 1.97 inch ID, 3 inches tall (part nbr PJM-VS-4) from PJMotorsports.com.
  • Red silicone hose (1 foot), 2 inch ID, and lined hose clamp (x4), 1.81 to 2.75 inch ID (part nbr 3613-2.75) from PegasusAutoRacing.com.
  • Air horn screens 70 mm weber intake 48/51 ID (part nbr 16627) from RacingBeat.com.
  • Velocity stack 3.5 inch pre-filter (part nbr F192) from Filterwears.com.
Create the velocity stack assemblies to be clamped to each throttle body, and then clamp each to a throttle body.
  1. Measure and cut sections of silicone hose such that you have a total length of 4.5 inches when each is clamped to a velocity stack. An effective method of cutting the silicone hose is to snug a hose clamp onto the hose against the line to be cut, and then cut along the clamp using a very sharp utility knife, preferably with a new blade. Clamp the silicone hose sections to the velocity stacks.
  2. Snug a clamp onto the throttle body end of each silicone hose section. Loose enough such that each section will fit onto a throttle body, and tight enough that it stays in position for final assembly. And position the tightening screw such that it is accessible when placed on the throttle body.
  3. Fit the screens to the end of each velocity stack.
    IMG 1922
  4. Fit the pre-filters over each screen. You now have two velocity stack assemblies ready for final installation.
    IMG 1923
  5. Clamp each assembly to a throttle body – right one first, then the left. I used a little silicone on the inside edge of each hose to aid in slipping each assembly onto the throttle body.
    IMG 1929 IMG 1934
Looking forward to the next ride!
 
The Sport likes the new intakes. First ride with them on today and it does feel like it is a happier machine. I know I enjoyed the ride!
 
That is an interesting set up.
I can't see replacing a well designed air box with stacks like that, but if it floats your boat have fun.
The sound of intakes can be fun.
Just not sure if it is worth the likely loss in flow.
 
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