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Evo air box mod RSVR gen 2
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albrown001 View Drop Down
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    Posted: 19 Mar 2018 at 21:45
Haven't posted for awhile. I hope you like this one. I call this the mega evo air box mod (if it works) Smile

http://www.sealsdirect.co.uk/contact.asp

Stick the EN84 6mm expanding cord in to the original seal groove. Obviously take the old one out.





Take your SRS1916 srs118 sponge rubber seal and stuff your ENC86 expanding cord 10mm inside of it. You can use rods or a bit of string to do this.







Anyone who has every owned an remote control car will know what this stuff is. This stuff is tire glue. Its what you use to glue your tires on with. This one is made by Team Losi. Its basically super glue but its a lot cheaper and you get a lot more of it.



What this stuff is also good for is sticking p shaped neoprene rubber to the underside of evo air box frames... Smile





The glue is really strong. But when its bolted up the frame also presses down on to the rubber and also on top of the seal on the air box.





How cool is that? Call me old fashioned. But I think that how the setup should be... I don't know if it actually works but I have to push the tank down quite hard and you can feel the seal touching as soon as you start to lower the tank. Especially at the front. But the foam will squash down even with the expanding cord in there.

I am certain that the plastic frame that holds the air filter in place flexes under pressure from the air. Next step is to make up an alloy frame that will not buckle under pressure to replace the OEM plastic one. I will hold it in place with the cable tie set up I currently use to help stop the plastic frame from bending.

Hope you like the post guys Thumbs Up

Roll on summer... 
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robbiersv View Drop Down
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Impressive! As they say if it looks right it is right and it looks spot on
The mille high club.www.apriliaperformance.co.uk.www.rsvr.net
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dog78 View Drop Down
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Points: 1520 		Post Options Post Options   Thanks (0) Thanks(0)   Quote dog78 Quote  Post ReplyReply Direct Link To This Post Posted: 01 Apr 2018 at 16:21
Hi Andy, that's great job you made of that.
I reckon that's a lot better than the EVO kit at least it will maintain some pressure.
I have something similar and have made some clamp to hold the airfiter down. I have now got a Ironbite which I haven't used yet saving it for my big Bore build.
How did your anodised frame come out?
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albrown001 View Drop Down
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Points: 539 		Post Options Post Options   Thanks (0) Thanks(0)   Quote albrown001 Quote  Post ReplyReply Direct Link To This Post Posted: 02 Jan 2019 at 00:13
Happy New Year everyone. Hi 'Dog' nice mod m8. Heres something that will improve it.

Drill a hole each side of the air box here (I did cover this earlier but here it is again)



Buy a K & N filter. Its the only filter purposely designed to fit the airbox properly and is not just a copy of the OEM filter that doesn't. Everything else is crap in my view purely because of this



Make up an alloy air filter holder that is the exact size of the outside of the air filter. The original plastic one is too big and not strong enough and flexes. You can polish out the silicone that comes out black out of the weld joints and makes the surface black if you get it anodised. I couldn't be arsed... 




Press your K & N air filter in to your airbox housing



Press the alloy air filter bracket on top of the air filter



Cable tie in place



I'll get round to making up a nice bracket and some sort of fixing at some point. But nothing is going to get through that now except through the filter element
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dog78 View Drop Down
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Points: 1520 		Post Options Post Options   Thanks (0) Thanks(0)   Quote dog78 Quote  Post ReplyReply Direct Link To This Post Posted: 02 Jan 2019 at 00:24
Nice job that , that bit of oem plastic is rubbish . When you think of the air pressure it just lifts the sides up and then you got sh*t in the airbox.  Make sure them cable ties don't snap and get sucked in. I like the metal bracket you made for it ,like you said when you get some bracket to hold that metal suround down be way better than the oem flimsy suround. 
Great job  👌✌
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albrown001 View Drop Down
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I have tried just about every air filter for the OEM air box that there is. Here is a picture of my pipercross, OEM and K @ N. I found that the K & N is the only one that you can totally rely on that will not let  anything past the seal. Anything else can and do move



No worries m8. Just trying to help Thumbs Up
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dog78 View Drop Down
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Points: 1520 		Post Options Post Options   Thanks (0) Thanks(0)   Quote dog78 Quote  Post ReplyReply Direct Link To This Post Posted: 02 Jan 2019 at 00:32
That's what I found that they are all a different fit ,some good and some bad .
I like the idea of the metal suround,  that will be the next thing I shall make for the airbox , it would be much better not flexing like the plastic . Thanks for that 👍
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albrown001 View Drop Down
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Originally posted by dog78 dog78 wrote:

Nice job that , that bit of oem plastic is rubbish . When you think of the air pressure it just lifts the sides up and then you got sh*t in the airbox.  Make sure them cable ties don't snap and get sucked in. I like the metal bracket you made for it ,like you said when you get some bracket to hold that metal suround down be way better than the oem flimsy suround. 
Great job  👌✌

Yes you are totally right m8. I have ran it with the other set up for awhile now so think that the cable ties are ok. But you are right though, its not the gold solution. I would prefer to use a proper bracket but just haven't got round to it yet. I am going to get some thicker cable ties just to make sure that they can't break. I am also using 3. So they are always attached to the air box as the square locking block on them that your thread the other end of the tie through cannot go through the hole I drilled. 

I probably should have mentioned not to drill a hole bigger than the end of your cable ties and make sure that you use at least 2. Bit I did think about that, just didn't mention it. I probably wouldn't have mentioned it if you hadn't had brought that one up. Cheers m8. Thank you for the comments and I am sure that has helped to explain things even more  Hug
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albrown001 View Drop Down
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You can get the angle alloy from ebay. I bought 10mm x 10mm x 2mm thick x 1m long
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Originally posted by albrown001 albrown001 wrote:

I am certain that the plastic frame that holds the air filter in place flexes under pressure from the air. Next step is to make up an alloy frame that will not buckle under pressure to replace the OEM plastic one. I will hold it in place with the cable tie set up I currently use to help stop the plastic frame from bending.
Just askin....

Wouldn't it be easier to fashion a cross-spar to the alloy rim to hold the filter against its flange (cf. http://https://www.apriliaperformance.co.uk/aprilia-performance-airbox-kit-gen-2-to-fit-rsv-04.html). It surely wouldn't be difficult to weld a spar across your existing rim.

FWIW, I smear red rubber grease over the rubber part to effect a good seal - a bit messy, but it keeps the rubber from perishing and can be easily cleaned up when required.
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Sorry, duff link:
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'06 Aprilia RSV 1000 R Factory 'Nibelung'
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I just lockwired the the plastic filter covers front edge under the front plate screws. Neat and no lift 
Aprilia RSVR Factory 2007 V2 1060cc Big Bore
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Cheers for the comments. I don’t like the crossbar idea as you have to undo your entire evo airbox frame. It’s crap and I don’t like it. The oem frame when cold might feel sort of ridgid but when it’s hot it may as well be made out of plasyetsceine and it flexes. Because the airfilter is made out of rubber it will flex too. Especially with a 100+ mph hurricane pushing on it 🙂
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Originally posted by albrown001 albrown001 wrote:

I don’t like the crossbar idea as you have to undo your entire evo airbox frame.
Are 7 screws that big a deal? The bar's a simple solution that works. How often are you changing your air filter? Is there a dust bowl in Dorset?

Originally posted by albrown001 albrown001 wrote:

Especially with a 100+ mph hurricane pushing on it
I wonder whether most of us realise just how much (i.e. how little) over-pressure the air box ram-effect produces. My reference is 'Motorcycle Handling and Chassis Design', Tony Foale, 2006. Fig 5.5 shows that at 100 mph (161 kph), the over pressure of a 250cc GP bike was a measured 0.54 psi (37 mbar). Hardly a hurricane, I would have thought!
Over pressure
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Originally posted by albrown001 albrown001 wrote:

Especially with a 100+ mph hurricane pushing on it
I wonder whether most of us realise just how much (i.e. how little) over-pressure the air box ram-effect produces. My reference is 'Motorcycle Handling and Chassis Design', Tony Foale, 2006. Fig 5.5 shows that at 100 mph (161 kph), the over pressure of a 250cc GP bike was a measured 0.54 psi (37 mbar). Hardly a hurricane, I would have thought!
Over pressure
[/QUOTE] wow I didn't realise that. Tbf I assumed a greater amount was through the airbox itself. One of mine has a bar holding the filter down, actually two do and the third was just lockwire 
Aprilia RSVR Factory 2007 V2 1060cc Big Bore
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albrown001 View Drop Down
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2500 mile update...

This is the first time that I have lifted the tank for 2500 miles and that is the condition of the air box. All the foam has compressed down a little and the tank is easier to lift and put down. But you can still feel a lot of resistance. I am pretty confident that this mod works as there is no dust in there at all. 





Only thing that I have noticed is there is a lot of pressure on the rubber on the left side and it has started to pull the rubber a little. I don't think this would happen if you didn't put the solid rubber inside like I did. But that said, you get a really good seal with the solid rubber inside. It just makes it a really tight fit between the tank and air box thats all.



You can see where the rubber has started to tear slightly but its still good. I think the idea of the cross beam is a really good idea now having had a second look at it. I'm currently looking at a making something up that will press down on to the air filter frame. But at the moment the cable ties are working fine. I also might put a bolt and lock nut across where the oil breather pipe foam is and remove the cable tie that is in there as well so its more permanent. You definitely get more bottom end to mid using the tank as the air box.
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