hi all, looking for some advice on what to do concerning the air box on my zx10 powered car, at the mo we have a custom made air box which is catching the underside of the bonnet and also the aluminium is fracturing from vibration, so i,m going to have a redesign of my inlet system, the bike was designed to run the kawaski ram air system which i think would be good to keep anyone know what diameter the feed needs to be?? at the mo were running about 3'' diameter on our inlet which feeds the airbox, i have read somewhere before that these fuel injected engines run much better with a airbox rather than just a filter on top, anyone shed any light on this ???
what i have planned at the moment is to run twin inlets fed from the bonnet via twin scoops around 3'' each 6'' in total to a custom made filter housing holding a panel filter then reducing that down to a 4-5'' pipe on to a kind of plenum chamber which will be connected to the throttle bodies,

any help or advise very welcome cheers.....

No experience with the ZX10 engine in particular, but can certainly confirm bike engines run much better with an airbox rather than direct filter, with the ZZR1400 airbox volume should be around 8 litres, would expect probs similar or a little less for the ZX10. Ram air doesn't make much difference even at very high speeds it's only around 4bhp IIRC, but obviously drawing fresh cool air from outside rather than hot air from under the bonnet will help so I would stick with the external scoops idea. HTH

Hi

I personally feel a properly sized air-box with filter and inlet being fed from a cold external feed, is a must.

It could be made from a composite material, you could bolt a composite air-box to the ZX10R inlet face plate and have the rubber gasket that is already there to help add some vibration damping.

Then you could also shape and size a composite filter box to suit your under-bonnet height restrictions, but still obtain an ideal volume in liters.

For me I would get a black plastic bag and fill it with x amount of liters of expanded foam and place it over the throttle bodies and throw the bonnet on and use the hardened shape as an approximate means to make a mould. from which your air-box would be made from.

The moulded air-box could also be mounted on rubber bobbins to help with vibration issues and the composite (be it GRP or carbon/kevlar) would take away the issue of Ally fracturing.

the air-box could then be fed from the outside air by means of a suitably sized tubular duct with an inline filter.

cheers

Cheers guys thanks for your input the plastic bag idea is great thks...

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Originally posted by turbo911
Cheers guys thanks for your input the plastic bag idea is great thks...

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Originally posted by matt_gsxr

Please video your exploits with the expanding foam. Always starts out looking easy and ends chaotic.

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sounds ike a disaster waiting to happen if that foam leaks out it will stick to my immaculate engine bay like poo to a blanket!!!!

I made one with expanding foam for my ZX10 engined car. I used the base plate from the stock bike airbox and made up an oversized cardboard box in which I let the foam do its stuff. I then carved/sanded the block of foam to shape and covered it in GRP then hacked the foam out of the middle.

Here's the foam blank:



And here's the finished article:



The story and more pics are here http://www.furybusa.org.uk/blog/?p=2195

I'll probably redo it over the winter as I didn't make the GRP quite thick enough and it's cracked in places.

Many thanks.....