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

  1. #11
    Senior Member SEXT9's Avatar
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    Once I shaped the cardboard strips, I hot glued one of them to the plywood keeping the edges between the lines.

    Photo Jan 13, 11 57 38 AM.jpg

    Then did the other strip

    Photo Jan 13, 12 04 12 PM.jpg

    I did not hot glue the cut out side.

    Photo Jan 13, 12 04 19 PM.jpg

    The corner will be shaved cleaner later anyway.
    Last edited by SEXT9; 01-13-2018 at 04:23 PM.

  2. #12
    Senior Member SEXT9's Avatar
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    Since all of the electronics are in the air box on my bike. The tail section is empty except for the shock reservoir and electrical connector to the rear lighting. As a result I can remove the tail section in about 4 minutes. I brought it in and fastened it to my work frame and installed the seat.

    Photo Jan 13, 1 10 12 PM.jpg

    I then placed the rough air box base where it will be going.

    Photo Jan 13, 1 10 44 PM.jpg Photo Jan 13, 1 11 21 PM.jpg Photo Jan 13, 1 10 56 PM.jpg

    I had to make a few adjustments to the corner heights so the mounting pegs will fit properly in their location on the base.

  3. #13
    Senior Member SEXT9's Avatar
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    Photo Jan 13, 1 13 04 PM.jpg

    I traced the outline where the seat meets the base.

    Photo Jan 13, 1 15 01 PM.jpg

    Then cut it out and placed the base back on to see how it looks.

    Photo Jan 13, 1 15 44 PM.jpg

    While at this point mark from the inside where the holes will be.
    Last edited by SEXT9; 01-13-2018 at 06:01 PM.

  4. #14
    Senior Member SEXT9's Avatar
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    Once the holes were marked, I drilled them out with the Dremel tool and reinstalled the base.

    Photo Jan 13, 2 01 33 PM.jpg Photo Jan 13, 2 03 53 PM.jpg Photo Jan 13, 2 03 58 PM.jpg Photo Jan 13, 2 04 20 PM.jpg

    Then I hot glued a support between the base and the frame so the base will keep the proper angle while fitting EBR air box over it.

    Photo Jan 13, 2 17 59 PM.jpg
    Last edited by SEXT9; 01-13-2018 at 06:13 PM.

  5. #15
    Senior Member SEXT9's Avatar
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    This part I don't have a bunch of pictures for. Next remove the seat. The base should keep its angle underneath with the support.

    Photo Jan 04, 9 07 56 PM (1).jpg Photo Jan 04, 7 41 03 PM (1).jpg Photo Jan 04, 9 08 20 PM (1).jpg

    Then place the EBR air box over top of the base and loosely fasten it to the front mount on the frame by the fuel filler.

  6. #16
    Senior Member SEXT9's Avatar
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    I used a Dremel to trim up from the bottom of the EBR air box until it met the base. Once I got them to meet up I hot glued the inside seam between the EBR air box and the base. The hot glue works surprisingly well with the air box material.

    Photo Jan 13, 2 33 26 PM.jpg Photo Jan 13, 2 33 36 PM.jpg Photo Jan 13, 2 33 46 PM.jpg

    This one I've already started work on. It's been trimmed up some around the edges. The cardboard and plywood have been wetted out with epoxy to give them strength. Once dry, I will begin layering carbon fiber over for strength in the seams.

    You don't have to use carbon fiber. You can use whatever loose weave material you want. Spray on some adhesive to tack the material in place. Then wet that material with some epoxy. The combination will give the part seam and shape strength. The strength is need to keep heat and vibration from tearing the part apart.

    I'll post the final results of mine when done. These instructions will get you through fitting yours though. I hope you enjoyed the write up and can find ways to improve this process. Post up if you have any questions or comments.
    Last edited by SEXT9; 01-13-2018 at 07:10 PM.

  7. #17
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    Thank you for showing the process.

  8. #18
    Senior Member Cooter's Avatar
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    Wow! I didn't realize you had gone so far with the job. Looks good

  9. #19
    Senior Member Cooter's Avatar
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    I found some inspiration in this thread!
    JL3Pm6cuTaKT0FFiZZStvw by Cooter!, on Flickr
    aGGTyUmKQxe1sQAk192QcQ by Cooter!, on Flickr

    I just chopped the back off a Hotbodies cover (fiberglass and fit like crap). The front of the seat holds it super tight and perfectly, I haven't bothered with rear mounts yet.

  10. #20
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    What is that on the RH control between the kill switch and the starter?



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