Protodie GSXR 1000 new air box

[ProtoDie]

Thought I would share a project I have been working on since last July.

A big problem we had racing was how much dirt / mud would hit the air cleaner. High velocity Rooster tails from the car in front of you would send a hail storm of dirt in your face,,,,and everywhere else when running second

We raced GSXR 600 and would use an after market K&N oval filter with an outer wears cover.
Then we would wrap with a K&N foam outer wrap.
This worked real good, and we never had any dirt / sand make it's way past the filter setup.
But, we had to add guards to deflect the mud, dirt from the outside to prevent clogging it up.


I would have gone with the same set up, but the GSXR1000 throttle bodies are wider & the same filter set up would not work.

So,,,,,I decided to design up exactly what I wanted.

Filter used is from a Ford Focus 2006 2.0
K&N filter is around $35 and stock paper is,,??$15-20??
I used this because it was way cheaper than a GSXR filter and offered more air flow volume
I can get a stock one, or a K&N one for this, and afford to keep spares around.

Around this I have a pre filter K&N foam set up. This guards from 90% of the dirt coming in.
Main intake is bottom front of the set up, well protected from dirt roost.

The cover is really a dirt deflecter & not intended to form a perfect seal, but direct where the air intake is from.

With the tapered sides I can shim it, or raise it up to increase air flow if needed,,,I could have 1/4 to 3/8 showing around the edges if needed.
The foam pre-filter, will still guard against the majority of the dirt.

I have the stock GSXR air sensor mounted in the box, and the 3 main breather hoses also coming in to the box.

Bottom plate is machined for the stock rubber boots. I designed this seperatly to accomodate for different motors / throttle bodies

Customer this one is for, I designed a cad USMC logo for him,,,then had it polished / brushed aluminum.

Mine I plan on a GSXR 1000 logo like in the cad pics.

[ProtoDie]

More showing the guts of the set up

[ProtoDie]

some beyond the filter

[ProtoDie]

Forgot,,,cover ecthing is machined in , 1/16 deep. Customer wanted it painted red.
here is a pic before the red paint

[RickS.]

Nice, but won't any debris that gets past the pre filter pile up on top of the K&N? I haven't looked inside my stock gsxr air box yet, but on the Honda 954 the air came through the filter from below. This way any debris that got past the pre filter would always fall away from the main filter.
Looks like there would be plenty of room to do it that way inside that hood.

[ProtoDie]

Rick,
Yes, what ever gets past the Pre-filter, will get to the actual filter.
with this design, that should be very minimal.

The foam pre filter has worked very well for us, which is why I incorporated it into this design.

Reminds me,,, another design intent is that the stock air box is 11 screws, and the center one requiring a long screw driver.
This is 4 bolts to remove the dirt cover & check your filter.

[Akpilot]

Protodie,

Very nice! I like it, one question, is the red foam filter also between the airbox and the K&N filter so the air goes through the red foam twice? or is it cut out around the K&N.

Timly post as it gives me some ideas for my 3 cylinder.

Thanks
Wayne

[ProtoDie]

AK,
The pre filter covers the front bottom intake & all around the edges of the top cover.
After the air flow passes thru there, it goes thru the top of the square K&N filter to the next chamber/ air box / / throttle bodies

[Gene]

Nice looking work Jody. That should keep the dirt out and I'm looking forward to run reports from you and customers.

Semper Fi!

[K-fab]

Beautiful work Jodi.

Good to see someone else moving away from the old oiled, expensive K&N setups. I'm thinking the dry filter will really work well too. - and it's nice to be able to head to the local Vato-Zone and purchase a clean, new filter for less than half of the price of the K&N.