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Thread: Fitting an EBR Air Box Cover to a Buell XB

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    Senior Member SEXT9's Avatar
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    Fitting an EBR Air Box Cover to a Buell XB

    I recently fitted an EBR cover to my Buell XB12. It hasn't turned out so bad and some wondered how I did it.

    Photo Jan 11, 8 00 34 PM.jpg Photo Jan 11, 7 59 22 PM.jpg Photo Jan 11, 8 00 45 PM.jpg

    Here's a short write up on the process I used. It was my first time around. And I wasn't sure it was going to work. So, I didn't take pictures of the entire process. Hopefully, you will still be able to follow along.

    If anyone does this project in the future, you will hopefully enhance the project with a better process and materials. I only ask if you come up with a better way, give back what you got. Let the rest of the forum know so we can learn from each other.

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    Senior Member SEXT9's Avatar
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    I keep an old untitled frame around that I put legs on as stand to do projects on. It just keeps me from having to tear into my bike every time I have some creative idea. So you'll see that throughout some of my projects.

    The first thing I did was install some painters tape on the frame rails. Then installed the OEM air box.

    Photo Jan 04, 7 33 41 PM (1).jpg Photo Jan 04, 7 33 58 PM (1).jpg

    Then I made some marks where the air box ends and the seat meets up.

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    Next I installed the EBR air box to how it fit and where it will fall against the OEM marks.

    Photo Jan 04, 7 41 03 PM (1).jpg Photo Jan 04, 7 40 51 PM.jpg Photo Jan 04, 7 41 55 PM (1).jpg

    It's not bad. But the bottom of the cover hits against the frame causing it to stick away from the frame on the sides.

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    Senior Member SEXT9's Avatar
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    So I trimmed off the bottom mounting tabs with a Dremmel tool. This plastic is a lot thinner than Buell XB plastic. The Dremmel slices through very easily.

    Photo Jan 04, 9 07 56 PM (1).jpg Photo Jan 04, 9 08 09 PM (1).jpg Photo Jan 04, 9 08 20 PM (1).jpg

    The air box now sits flush against the frame. I then transferred the marks from where the XB air box and seat met to the EBR air box.

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    Next up I took a piece of plywood 12" x 8" x 11/32". Plywood might not be the ideal material. Anything a bit stiff and porous will work.

    Photo Jan 13, 11 03 01 AM.jpg Photo Jan 13, 11 06 03 AM.jpg Photo Jan 13, 11 09 59 AM.jpg

    I placed an XB air box on top of it and drew out the bottom shape. Then I cut out the inside portion.
    Last edited by SEXT9; 01-13-2018 at 03:14 PM.

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    I like the look

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    I then took an 8.5 x 11 notepad and tore the back off it.

    Photo Jan 13, 11 26 09 AM.jpgPhoto Jan 13, 11 30 29 AM.jpg

    I cut (2) 3cm or 1-1/8" strips off each side.
    Last edited by SEXT9; 01-13-2018 at 04:03 PM.

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    Next I took one of those strips and placed it along the tracing on the plywood I made from the XB air box. I made a mark for every over 45 degree bend in the shape.

    Photo Jan 13, 11 37 43 AM.jpg

    I used a ruler to keep my bends at a perpendicular angle on each mark.

    Photo Jan 13, 11 39 11 AM.jpg

    I then bent the strip until they matched the shape I was going for.

    Photo Jan 13, 11 42 24 AM.jpg
    Last edited by SEXT9; 01-13-2018 at 04:05 PM.

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    Attachments don't seem to be working, at least not coming up for me.

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    Quote Originally Posted by njloco View Post
    Attachments don't seem to be working, at least not coming up for me.
    I noticed the last 2 posts looked odd. I went back and reattached the images to their posts. Does that help?



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