View Full Version : Custom airbox cover

05-26-2009, 05:25 AM
Just thought I would show you guys what I've been up to...

First, I printed the logo, transferred it to a thin plastic I got from a sign shop, and then cut it out with an x-acto knife. Then spray glued it to the airbox cover, held it down with some masking tape, and let the glue set.


Then I busted out the Dremel with a roto-zip bit in it to cut out the basic pattern. Cleaned it up the best I could with a combination of the x-acto, 80 grit sandpaper, and some long-fiber fiberglass bondo. (see comments below regarding the roto-zip idea)


After much sanding, re-bondo'ing, and a significant amount of swearing I slapped some spot-putty on there to cover up my sanding and various other f-ups.


I would have to say after I sanded down the spot putty with a 220 grit it actually looked pretty good. I'm far too picky to leave it like it is, so there are going to be a few more rounds of spot putty and sanding before its ready for paint. But all in all I'm pretty happy with how its coming out.

Rinse and repeat for the other side...


Now, with all that being said, for the second one I went out and picked up a jigsaw and some wood/plastic scroll blades. It was way easier to control, and the results were 100 times cleaner. The Dremel with the roto-zip blades(?) was just far too hard to control, and I kept screwing up my work... hence the profanity, excessive bondo, and way too much time spent.

The general idea is to put a piece of expanded metal similar to the stock opening behind the Pegasus logos. Going to paint the metal the same orange color that I'm using for accents on the rest of the bike. I'm most likely going to chop up the inner airbox cover and throw some LED lighting in there as well... should look pretty cool when I'm done, and sound even better. =)

And no, that Kylon can in the background in the background is not what is going to be used to paint the bike, lol. It was used to duplicate my pattern I had cut.

Disclaimer: Some bike parts may have been harmed in the making of this tutorial.

05-26-2009, 05:27 AM
wow buellysses, that's awesome, you get a point for this one. Beautiful mod my friend [up][up]

05-26-2009, 05:31 AM
wow that looks like a fun project! I cant wait to see it when it's done!

I've been trying to find the stock mesh too. Let me know if you find some!

05-26-2009, 06:48 AM
Ya now you better give us an update picture and not leave us hanging and guessing ;)

05-26-2009, 12:36 PM

05-26-2009, 02:23 PM
I'm ordering my paint this morning, hopefully have this thing knocked out of the park by the end of the weekend. I'm missing some amazing riding weather.

I've been trying to keep pics of the whole process, so I'll definitely keep you guys posted.

05-26-2009, 05:08 PM
good looking bro, great work as well, are you going to but something behind it? like a screen or metal, might be cool?

05-26-2009, 05:16 PM
Yeah he said he would

The general idea is to put a piece of expanded metal similar to the stock opening behind the Pegasus logos. Going to paint the metal the same orange color that I'm using for accents on the rest of the bike.

05-26-2009, 05:19 PM
That looks really good! The stock mesh is kinda tough to find. I actually used some mesh gutter covering I got at a local hardware store. Just a thought.

05-26-2009, 05:24 PM
Looks awesome!

Mitchell, yours looks great too!

I'm jealous :(

05-26-2009, 05:44 PM
wow, i'm stupid!!

05-26-2009, 05:50 PM
looks good, Buellysses!

would also guess that a figure saw (hand) would be a more controlled job, too.

05-26-2009, 06:23 PM
I AM JEALOUS [smirk]

05-26-2009, 07:11 PM
What did you use for a border around your cutout? or is that just paint?

05-26-2009, 07:15 PM
Yeah, I had wanted to know the samething.

05-26-2009, 07:18 PM
mitchell that looks great. Did you paint the gutter mesh with chrome paint or anything? Also curious about the border.

05-26-2009, 07:27 PM
I was thinking of using either This (http://www.mcmaster.com/#92725t22/=21litb), or something like this (http://www.mcmaster.com/#9232t131/=21lowf)

Gotta love McMaster!

I would agree with you wholeheartedly Fox, but what fun is a project if you can't bleed a little bit?

I kinda stabbed my thumb with the x-acto. I left that step out of the instructions, and I would avoid trying it yourself.

05-26-2009, 08:01 PM
Hey Buellysses, it looks like your first link is the one. If it matches, you buy some and have left overs, can I buy some from you?

05-26-2009, 09:01 PM
Sounds like a plan. I certainly don't need a 4' x 3' sheet of it.

05-26-2009, 09:23 PM
I just used a black silicone on the underside and then put a little border around the outside. The mesh gets a little messy but is easy to clean up with a razor blade.

05-28-2009, 06:19 PM
These look great, with opening the outer or inner airbox to this much air, does this require a TPS reset or any other adjustments? I have a full race kit, exhaust, ECM, filter.


05-28-2009, 06:34 PM
its more air than what the race ecm is designed for, so a tune wouldnt hurt.

05-28-2009, 06:37 PM
How flimsy is the unconnected line of the wing? Seems like it would be pretty weak.

Looks sweet. Cut outs are getting better and better.

05-28-2009, 07:14 PM
The Wings are pretty floppy, but once I glue the metal backing behind them they should be just peachy... Im going to make sure I glue those down with a good epoxy. That should hold them in place nicely.

It's actually quite surprising how sturdy that plastic they use is, granted it's thick as hell, that helps.

05-28-2009, 07:21 PM
Great job... that is going to look fantastic once painted and installed! [up]

05-28-2009, 07:47 PM
yeah that should help. I went to the Home Depot to look for around for some screen mesh. Actually thinking of doing the mod myself.

with opening the outer or inner airbox to this much air, does this require a TPS reset or any other adjustments? I have a full race kit, exhaust, ECM, filter.

But I have the same issue, and not if I want to try screwing around with this yet

05-28-2009, 08:22 PM
TPS reset - It's almost a given you'll need to do one.

Custom map - If it runs rough. But, I'm like Dave, it can only help your bike.

05-28-2009, 08:44 PM
yeah, I'm looking to sell my bike in another 800 miles, not really trying to put more money into, if need be with a new custom map if you know what I mean. So I think I'll just play it safe and keep it as is.

05-28-2009, 09:17 PM
Looks good Buellysses I like it. Be forewarned you will be able to hear the intake valves open and close and its pretty loud unless you use ear plugs. Also if you where concerned about water getting in I drilled two #5 holes in the base at its lowest point in the back corners in case of rain. I have also rode in a few heavy rain storms without a problem. Not as much as a sputter. I used black rtv silicone to hold the mesh in place and it works just fine.

05-28-2009, 10:44 PM
Yeah, I was kinda wondering about the water issues with rain as well. Probably going to punch a couple holes in it for some drainage action.

As for the loudness... the more the merrier. Hopefully it doesn't drown out the Drummer. Just remember, if you think it's too loud I think your too old.

05-29-2009, 02:31 AM
I think the first link to the mesh is the one, the hexagonal type of screen might just match the stock opening.

I love the mod BTW!!!

05-29-2009, 03:14 AM
Just remember, if you think it's too loud I think your too old.

Bahaha I told my mom that the other day when she said my bike was too loud! (Race exhaust)

06-05-2009, 05:45 AM
Quick mock up. I think I'm still going to paint it orange to match the other accents.

I picked up my paint today ($170 for a sprayable quart of primer, just over a quart of matte clear, and a quart sprayable of a high build primer) Going to paint this f-ing thing tomorrow!


06-05-2009, 06:05 AM
that looks awesome. Let me know if you have any mesh left, PLEASE

06-05-2009, 02:12 PM
Check it out (http://www.buellxb.com/Buell-XB-Forum/Do-It-Yourself-Buell-Mods/Perforated-metal-sheets)

06-05-2009, 04:45 PM
replied in other post

06-08-2009, 04:39 AM
Son of a ****! I should have went with the hot-rod black paint without the clear coat... I was shooting the clearcoat on the frame (the last piece to be finished) when my gun ran out. When I mixed up the last batch I must have f-ed up the mix. It sprayed fine but the **** never hardened.

Hopefully I can let it sit for a day or two and let the stuff dry out so I can sand it off and re-shoot it. I really don't want to have to redo the whole damn thing.


06-08-2009, 03:45 PM

How are you planing on attaching the screen to the plastic. I asume that it'll be on the inside, any ideas yet?

06-08-2009, 04:05 PM
That sux Buellysses. Hope you do not have to respray the whole thing. Some advice next time if you do or if you paint later on. When I mix up paint, I mix in a seperate container and then pour into the gun. I always mix more than needed. You can mix in a sealable conatainer and it will stay good for a day or so. This also helps so that there is no tinit difference. Most auto body paint shops sell cups that have the marks for mixing already on them. They are the way to go.
Hope you get it straightened out soon.
Be sure to post pics when you are done.

06-08-2009, 04:44 PM
WOW that relly looks great! Can't wait to see the end result.


06-08-2009, 06:24 PM
I planned on attaching it inside using some black silicone. Or possibly an epoxy if I cant get the silicone to stick.

Yeah, I have the mixing cups, they are pretty much idiot proof. That is until you realize halfway through the mixing process that your reading the wrong ****ing scale, and try to re-adjust the mix with the other components.

According to the paint guy, I should be able to take a heat gun after it to get it to harden. Re-sand and re-shoot. I guess we'll have to give it a whirl.

Having never painted before, I had no idea how much I would need. So the best I could do is guess. If anyone cares, I repainted the frame, rear-sets, the sides of the chin fairing, the front fairing, the sides and top of the console, the rear loop, and the swingarm. I ended up using just about a quart of grey high-fill primer, just under a pint of base coat, and just over a half pint of clear. I did 2 coats of each.

I'll have some pics after tonight.

06-08-2009, 07:00 PM
Nice!!! By the way, email sent in response to yours.

06-12-2009, 04:53 PM
Here you go guys. Just have to put the mesh in!


Another look:


06-12-2009, 04:57 PM
Awesome! How much to have you do mine that way?

06-12-2009, 05:15 PM
Wow, looks great and nicely done. [up] Now just pics of it mounted on the Bike and I'll leave you alone. ;):D

06-12-2009, 05:36 PM
Superb job my friend. Now I can't wait until I receive my mesh from you so I can do a little something similiar, different design of course ;)[up]

06-12-2009, 06:46 PM
Would you really trust me to do this to yours? lol.

Painted or un-painted?

07-08-2009, 06:30 PM

I guess it was kinda a joke, should have been clearer. ;)

I think I can do it my self, what did you use for a template? Did you free hand it?

Eitherway I feel it's hands down one of the coolest mods I have ever seen on a buell.

What would you charge for the cut out, I can repaint it unless it makes sense to have you paint it as well. If you want you can email me to work this out.

I probably won't be doing this mod unitl this winter. I have huge plans to continue mod'n my bike. I want it to be unique as possible. Plus I love the half black half orange look.

A++ to ya!

10-12-2009, 10:41 PM
OMFG. very cool mods.

08-03-2010, 10:00 PM
Buellysses you got me wanting to do the samething but Im going to use a diffrent decal already started. Here are some photos, I just hope that it works.. let me know what you think..





08-03-2010, 10:12 PM
I love the cutting of the airbox, very cool.

08-04-2010, 01:32 PM
I think you have your work cut out for you. (ha ha)

If I were you I'd find a junk cover to practice on. There is a lot of detail there! You may want to avoid power tools on that one, a jigsaw takes off a lot of material in a hurry. Start with the horse body and work towards the feathers.

That's going to look pretty bad-ass if you can pull it off!

08-04-2010, 06:23 PM
yeah I dont think I'm got to use any power tools just a knife. I had 3 other covers but I sold then last week.. so I can't sucks for me, but I never back down from a challenge. I dont have much time to work on it though. I work 12 days 6 days a week and the days I have off I'm with the family. This one is going to take some time. but if it works out hell F@#king yeah..:D

08-19-2010, 07:25 PM
hmmmm, good luck with eye and nose.

08-20-2010, 01:14 PM
You want see the eye or the nose. just the out line of the head is all that you will see. the only sad thing is that i'm not going to start till it rains..:(

08-23-2010, 04:45 AM
'Such a useful thread I’ve been looking this topic everywhere!'

expanded metal (http://www.cadischmda.com/meshtec.asp)

architectural metal (http://www.cadischmda.com)

metal cladding (http://www.cadischmda.com)