The inspiration of this AC came from Streetfighter06. He had a similar setup on his ride and I think it looks as good as any big name ACs out there but for a fraction of the cost.
It took me a couple years to get around to actually work on this. Ironically, the weekend after I bought my filter and end cap, I saw another member here had gotten the same idea. For that, I need to thank groverhd for putting his thread up here and letting me see the final appearance. See, I was trying to determine if I wanted to vent through breather bolts, an independent filter or directly into the intake like the stock set-up. I decided to go the breather bolt direction.

Time beginning to end, a little less than an hour. Cost, roughly $65.


Following is a complete step-by-step photo process: (apparently, I am limited to 20 pictures, so I had to cut a few out)

Remove two allen-head screws holding the AC cover.

Remove 3 torque screws holding the filter

Carefully remove filter gasket (will be reused)

Remove two breather bolts

Back plate slides straight off

New Filter (Pep Boys/$19) and drain cap (Home Depot/$1.50)

Use gasket as a template for drilling holes in the drain cap. Make sure gasket is facing correctly. The extra hole should be positioned in the upper-right.

The filter can accommodate multiple size mounts: 3”, 3.5” & 4”. There are removable rings on the backside to allow the opening changes. Since the end-cap I used has a 3.5” outside diameter, I needed to remove the center ring from the filter.

Place the end-cap into the filter and trace the edge to get a cut line

End-cap marked and ready to go

Use a 2” hole saw for the center cut-out then drill the mounting holes

After removing all stray pvc splinters, test fit the holes

Small hand saw to cut the cap down to size

Roughed out custom mounting plate

All edges and mounting surface sanded smooth (started with 220 grit, finished with 600)

The original screws are too long for this set-up, so you need three ¼” X ½” long, course thread screws (Home Depot/$2)

Breather Bolts from DK Custom ($38) BTW, ordered LATE Tuesday night … arrived Friday morning. Amazing shipping time. You guys rock! Thanks Kevin!!

Mounting plate and Breather bolts installed

Air filter slips on and is held on by a stainless steel clamp. It extends out the same as the stock ham can but has a smaller overall footprint.

 

Nice and clean, I'm liking those breather bolts.

 

Looks Good! Thanks for the nice photos.

 

Nice an easy, great pics, and instructions.

 

Looks good. Great job !!!

 

Wow looks really good! I eventually broke down and bought a dremel, man did it make jobs similar to this one go so nice and easy! Looks great man! Are you changing the AFR at all?

 

Nice write up. I plan the same thing when I get my iron but planning on sanding and painting the chrome parts on the filter and making the mount out of metal

 

Well, already had the 2:1 exhaust and a fuel pak to eliminate decel pop. The bike had been running a bit rich w the stock ac. Since there is no true setting on the fuel pak for pipes and stock ac, the fuel ratio should be better now.

The bike feels good, soubds good and no hesitation or popping after the change...so I think this will be ok.


Forgot to mention in the original write up. Use a drop of blue lock tite on the bolts to keep everything in place with the engine vibrations. Also, I am not a chrome fan....I see some sanding and flat black in my near future.

 

Nice !! What is the end cap and where do you get it?

 

This is a 3" PVC drain cap found in the plumbing section of Home Depot or even Menards or Lowes ... costs run between $1.50-$3. I found mine at Home Depot.