DIY Air Induction Block Off Plates

[MrM0t0]

I made a set of Air Induction System block-off plates for my FJR. Right now I have more time than money, so I made my own. I'd have preferred Wynpro's (he's just a 1/2 hour from me).

I started by covering a piece of 1/8" aluminum with masking tape and then scribing around the original hose ports with a tiny exacto blade. Next I took a jig saw with a hacksaw blade installed to rough cut them. Then it was on to the fun part with my DIY milling machine fitted with a carbide bit.

After the milling

Comparo to the OEM hose ports

Glam studio shot after polishing

Installed. The stock I had was thinner than the OEM ports, and the bolts are drilled to the minimum depth, so I had to add a washer under each one.

 

[PTParks]

Raw materials, a little time and effort, and TADA! You've saved a couple of bucks and have the satisfaction of doing it yourself. Bravo!!!

 

[mdisher]

:clapping:

 

[vabrzn]

Nice job

 

[RossKean]

1/8" was too thin for the screws. Is 1/4" too much? Just in case I decide to make my own, I just want to use the right thickness of material.

 

[MrM0t0]

1/8" was too thin for the screws. Is 1/4" too much? Just in case I decide to make my own, I just want to use the right thickness of material.

I think 1/4" would be perfect. I Think that's closer to the actual thickness of the intake ports you're replacing.

 

[mferriter]

I agree that 1/8" is too thin. If you're mill can handle 1/4 go with that, or maybe double them up. The good thing now is that you can use your 1/8" plates as a template.

 

[serhan]

They do look great! What do they do?

Is it related to removing PAIR?

S.

 

[MrM0t0]

I'm still getting familiar with the jargon here. What is PAIR?

 

[Crash Cash]

I'm still getting familiar with the jargon here. What is PAIR?

Pulsed Air Induction Reed valve. These are the valves you're blocking off. And I gotta say I'm stealing the idea for that milling setup! Looks like something straight out of MAKE magazine!

 

[MrM0t0]

I'm still getting familiar with the jargon here. What is PAIR?

Pulsed Air Induction Reed valve. These are the valves you're blocking off. And I gotta say I'm stealing the idea for that milling setup! Looks like something straight out of MAKE magazine!

I've done a lot of milling with that little Dremel knockoff, and for this project the idea came to me to mount the "vise" to an upright at an eyeballed 90 degrees. It worked great, but you need gloves as the pieces do jump off the bit at some angles.

 

[NSrider]

1/8" was too thin for the screws. Is 1/4" too much? Just in case I decide to make my own, I just want to use the right thickness of material.

1/4" is perfect Ross, here are a couple pics of some I made a couple years ago. If you leave the reeds in you will need to make a couple counterbore' underneath the block off plates.

 

[dannymax]

What about 1/8" plates with the oem housings bolted over them? Would that work?

I don't understand what this mod will do....is it a GenII thing?

 

[dannymax]

What about 1/8" plates with the oem housings bolted over them? Would that work?

I don't understand what this mod will do....is it a GenII thing?

Never mind, just answered my own question. I love the idea of having less crap on top of the engine....if I can remove enough of it maybe I won't have to pull the motor for the next valve check!

 

[RossKean]

1/8" was too thin for the screws. Is 1/4" too much? Just in case I decide to make my own, I just want to use the right thickness of material.

1/4" is perfect Ross, here are a couple pics of some I made a couple years ago. If you leave the reeds in you will need to make a couple counterbore' underneath the block off plates.

I haven't had them off but I'm sure the "counterbore" will make sense once I see what's underneath. Yet another winter project...

Ross