open cage

B

bartiger

fast rider
Joined
Oct 8, 2021
Messages
99
Location
Bavaria
hi,
we all know, that we could easily gain a few HP and tourque on low end but also over the whole rev range by removeing the lid from our airbox.
we all know this pirate racing vid..
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red = with lid blue = without lid (credits by pirate racing)

But it's not quiet es good as it could be.
By removing the lid you are taking an additional hole from about 82 cm² (green), but effective you only got about additional 34 cm² (blue).
The cage, that holds the filter itself in place are not designed to let max airflow through his handle (which is right under the lid).
So i wonder if we could improve our airflow by modding the cage or replacing it (red).
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As iam new to 3d printing and shapping, i did a prototype and printed it in M 1:2.

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(yeah i know, i still got some troubles with cura..)

The design isn't final, but i managed an effectiv airflow area from 68 cm², what is an increase of 100% (with original cage 34 cm²).

I think it's the best possibility to increase airflow, without cutting big holes into your airbox like pirate racing stage 1 or in the Duke 690 PP raceline Aribox..

it's just fun..
 

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Look at the two curves. The increase is huge at low flow and decreases at higher flow. If the max flow rate would be the bottleneck, the opposite would be the case. Turbulence in the small airbox is probably responsible for the poor performance at low/mid rpm. How your new cage design will perform, can only be proofed on a dyno.
 
Yes, only a Dyno would show the difference, but it's a long way to go till there..
I think airflow is crucial at low and mid revs, at high rpms it got enough inertia to suck even through thin funnels..
Maybe airflow is the false term?
 
I wonder why engineers designed the original cage like this. With the lid on, it creates a kind of a „pocket“ in the airbox.
Your new design is intended for use without the lid - right? Sorry I missed that at the beginning.
 
Hey don't worry.. yes it should be used without lid or an (maybe 10mm) elevated lid.
The original cage is really smart, it's funtional, cheap to produce and easy to handle. The diameter of the original airintake (funnels) is a lot smaller than the holes located at the side of the cage.
I tried also to rounded the sides to calm down the air.
 

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I'm thinking about some trumpets to replace the funnels and to lead the air more to the side holes of the cage.
At the Stock airbox there are a lot of sharp edges, and a 90 degree corner.. and yes I have lots of fun to think about and print some parts..
 

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First 1:1 Prototyp for fitment..
 

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Only thinking of the business opportunities.
With dyno sheet showing 2-3 horsepower gain, you could sell them for 80-90 dollars.
 
of course a dyno would be cool to proof some results.
But it tooks minimum three runs (one original with lid, one original without lid, one with the mod without cage).. next dyno ist about 100 km and one run is 60€..
don't know if it's worth it, i make this just for fun, and iam not yet done..
 
Good news snug fit..
Bad news got much more to consider😅
 

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got to change the left and right profil to a slightly different location and shape.. didn't consider the shape of the seat (aka new lid)..
i got something like this in mind
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Me encanta ver cuán creativas e ingeniosas son las personas aquí.
Si tienes una idea en la cabeza y eres capaz de hacerla posible, sea o no realmente efectiva o útil, es admirable.
Realmente me encanta ver como cada uno aporta su granito de arena.
 
I love seeing how creative and resourceful the people here are.
If you have an idea in your head and you are able to make it possible, whether or not it is really effective or useful, that is admirable.
I really love to see how each one contributes their grain of sand.
 
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