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Renegade Airbox Mod

29266 Views 37 Replies 12 Participants Last post by  1Bad1000Xxc
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Well, now that the CVT has been snorkeled, I needed to complete the project by waterproofing the air intake. Rather than raising the factory inlet, I opted to remove it entirely and open up the airbox lid. This serves two purposes in that the air inlet will be higher than I could've gotten it under the pod, and the CVT intake and engine intake won't be competing for the same air.

First step is to remove the front plastic, side panel from the left side and the outer cover of the box (inside left front fender) that contains the factory engine and CVT intakes.. You will now be able to see the factory "snorkel" running from the airbox to the underside of the left front fender.
http://i304.photobucket.com/albums/nn191/4stangs4/IM001626.jpg


It is secured by a 10mm bolt and a pushpin, remove them. There are 4 rivets holding it to the airbox. I removed the airbox lid, removed the factory air filter and placed a clean rag in the intake to prevent any debris from entering. Now, you can drill out the rivets, remove the factory "snorkel" and clean off the gasket material from the airbox.
http://i304.photobucket.com/albums/nn191/4stangs4/IM001781.jpg


I used a piece of 1/8" plastic to cover the hole. Secured it to the airbox with 3 rivets (in new holes) and sealed the perimeter and all holes with black RTV.
http://i304.photobucket.com/albums/nn191/4stangs4/IM001780.jpg


There are several companies that make material to cover the openings that will be cut into the airbox lid. My research led me to choose water repellent FrogzSkin intake screens (Frogzskin, The best in snowmobile accessories!) which are manufactured by GTL, Inc. in Minnesota. I spoke with the owner, Wayne Nicholson, before purchasing them and he was very insightful. His product was developed for use on snowmobiles, primarily to aid engine cooling while preventing snow & water from passing through. This was a key factor in my decision to use the FrogzSkin brand, along with the fact that these vents are flexible and the Can Am airbox lid has many contours to it.
http://i304.photobucket.com/albums/nn191/4stangs4/IM001755.jpg

http://i304.photobucket.com/albums/nn191/4stangs4/IM001756.jpg

http://i304.photobucket.com/albums/nn191/4stangs4/IM001757.jpg


With the airbox lid removed, I chose the locations for the intake screens. I used three of the 2.5" (outside diameter) FrogzSkins after doing a few math problems. The stock opening (that we covered over) was 1" X 3.25", giving us a total area of 3.25 square inches. The intake screens have an inside diameter of 1.5", which yields a total area of 1.767" (radius squared times pi or .75 X .75 = .5625, .5625 X 3.1416 = 1.767). I had to get my kids to help on that part, since my math skills hadn't been tested in some time. :: D OK, so each screen has an area of roughly 1.75" and I believe Wayne mentioned an estimated 30% restriction from the screen material (I may be off on that figure, don't quote me). Total area of the three screens will be 5.25", less 30% leaves us 3.675 square inches, which is almost a half inch larger than stock. This represents a 13% increase in the total area, even with the 30% restriction. Hopefully, this won't require the addition of a fuel controller, I will be checking the plugs frequently to be sure. Here's where I chose to put them:
http://i304.photobucket.com/albums/nn191/4stangs4/IM001783.jpg


I used a 1 1/2" holesaw after drilling a pilot hole in the center of the holes I marked. Clean off all of the plastic shavings and burs around your new holes.
http://i304.photobucket.com/albums/nn191/4stangs4/IM001784.jpg


The instructions included with the FrogzSkin screens are very detailed and explain that the area around the holes should be clean and prepared with denatured alcohol for best results. I was pleasantly surprised at the bonding strength of the industrial grade adhesive used on the product. The instructions give a thorough explanation of the best way to apply the screens on the first attempt. One area that I must note is on the hole in the curved area of the lid. The hole that I drilled is actually elongated larger than 1.5", due to the curvature. The only way that I thought I could prevent this would be to use a Dremel to make the hole, but I felt my results would be better by just centering the screen over the slightly longer hole. It was off slightly less than 1/8" on top and bottom, the sides were dead on.
http://i304.photobucket.com/albums/nn191/4stangs4/IM001785.jpg


I also installed a Uni filter after many recommendations regarding the stock filter's ineffectiveness at catching small particles.
http://i304.photobucket.com/albums/nn191/4stangs4/IM001788-1.jpg


I've only tested this setup on a few bursts up and down the street, as I have yet another torn CV boot. :protest: However, I can say, without a doubt, there is NO loss of power. In fact, I tend to feel there is a subtle increase, as the front end came up quite effortlessly. I usually don't "hotdog" in front of my neighbors, so I wasn't trying to wheelie, it just seemed to happen easier than it used to. As I stated earlier, I will be monitoring the plugs to detect any lean condition due to the increased airflow, and I'll post any findings here. Once I get the CV boot replaced, I plan on finding some deep spots to give the CVT snorkels and airbox mod a thorough workout!
:club:
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Once again, great write-up. But I've got some questions. :wave: Do the "skins" have a pre-applied idustrial adhesive or is it a tube that you had to apply? Also, you mentioned one of the holes was elongated. I'm not sure I understand if you ment you covered the hole with only 1/8" overlap or if you were short 1/8". If you were short, how did you make up the difference?
Once again, great write-up. But I've got some questions. :wave: Do the "skins" have a pre-applied idustrial adhesive or is it a tube that you had to apply? Also, you mentioned one of the holes was elongated. I'm not sure I understand if you ment you covered the hole with only 1/8" overlap or if you were short 1/8". If you were short, how did you make up the difference?
thanks sarge! yes, the industrial grade adhesive is already on the FrogzSkin screens - just peel 'n stick. i (unintentionally) let a small area adhere to my finger, that glue is pretty strong! they have a half inch border around the screen that is adhesive backed. with the lower hole being elongated, i split the difference and there was about 1/16" at the top and 1/16" at the bottom where the inside of the adhesive ring wasn't glued to anything. i realized the hole would be off a little, but figured it would still be better than if i were to freehand it with the dremel. hope this answers your question, BG!
nice write up...just waiting for some test results before I buy up my frogz skin vents...I talked to wayne today..seems like a great guy...

hope this works for you cause if it does I think Wayne will be getting alot of business...
nice write up...just waiting for some test results before I buy up my frogz skin vents...I talked to wayne today..seems like a great guy...

hope this works for you cause if it does I think Wayne will be getting alot of business...
thanks stiff, nice to see you over here! :thumbup: i've got a lot going on, but i'll try to find a local dealer with the cv boot in stock, so i can get some riding on those FrogzSkins. have you checked out Buster's renegade - Project X? it's one good-lookin' bike! i'll definitely keep you posted on the airbox, how'd your snorkel turn out?
Yeah Ive seen busters bike...its a nice ride..Im not big on decals but it does look nice...and if your a racer well I think you need them hhahah...

Havent started the snorkeling yet but plan on it here during the week...

and yeah please let me know on the vents :)

Stiff
Stray, another great write-up dude with great images along the way.

Stiff, glad to see you over here!
Thanks Stray. That answered my questions. Now, I'm anxious to see how they work for you. Do you already have your mud hole picked out? :evil6:
Stray, another great write-up dude with great images along the way.

Stiff, glad to see you over here!
thanks, Buster!

Thanks Stray. That answered my questions. Now, I'm anxious to see how they work for you. Do you already have your mud hole picked out? :evil6:
yeah, there's a few spots! ;;s;; i'll try not to get too carried away, especially while i still have the ITP holeshots - i know these tires aren't well-suited for the deep mud. i'm also starting to develop a torn cv boot phobia. :protest: i believe i have tracked down a supplier that will allow me to purchase a small quantity of hdpe sheets. hopefully, soon i will be fabricating some full skids and, more importantly, better cv guards.

:rockon:
Great write up Stray!

Holy shiznit, are we being invaded by Can Am riders here? LOL

Welcome to the site Stiffler.
I sure hope so. Keep 'em comin!

Holy shiznit, are we being invaded by Can Am riders here? LOL
Great write up Stray!

Holy shiznit, are we being invaded by Can Am riders here? LOL

Welcome to the site Stiffler.
thanks grizzlywizard! those v-forces better watch out!

:rotfl:
I sure hope so. Keep 'em comin!

I guess I'll have to get my Yami and Kawie guys to come over and outflank ya! :beer"
I guess I'll have to get my Yami and Kawie guys to come over and outflank ya! :beer"
I got your back!
I guess I'll have to get my Yami and Kawie guys to come over and outflank ya! :beer"
YOu may outflank us, but you won't out run us. :evil6:
I guess I'll have to get my Yami and Kawie guys to come over and outflank ya! :beer"
hope this wasn't one of your yamaha buddies... :rotfl:


04260915183g2.flv video by 4stangs4 - Photobucket






lol, one of my (outlander) buddies sent me this. it was from their ride last weekend. said the rhino backfired once, then... up in flames!

sorry bout the poor quality - was taken on a cell phone then converted to avi.
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Bring it. :evil7:
I will be at Hatfield and McCoy from Wednesday till Sunday this week. There is plenty of room in the cabin to stay also.:beer"
I will be at Hatfield and McCoy from Wednesday till Sunday this week. There is plenty of room in the cabin to stay also.:beer"
You know I'm out of town.
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