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airbox removal with custom muffled water proof filter box

10K views 14 replies 9 participants last post by  backwoods_rzr  
#1 · (Edited)
what is it you may ask?? is it a lamp shade? thats the first thing my smarty wife said with a big grin.... no , its my idea of the absolute fix for the RZR dust issue and something close to what polaris should have" in my opinion" installed from the factory (but maybe not as lamp looking)
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its an extremely high flow and completely waterproof airbox eliminator filter system with an intake noise baffle. I was tired of worrying about my filter and checking it all the time and glueing my filter box lid back on with silicone so this is what I came up with.
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turns out the rubber boot between the throttle body and the original airbox accepts a 3'in aluminum tube perfectly. 4 feet of tubing ran me $20 at a local material supply store. the rubber elbow is a rubber 3 1/2 inch 90% pipe elbow which I found at my local hardware store for $12. the filter I used is a k&n "style" filter with one big difference. iinstead of using a single layer of loosely woven gauze for a filter element, this filter uses 3 layers of tightly woven gauze so you cant see "daylight " through it like you can with a K&N. the filter element itself was for a 2004 ford diesel truck and is huge at 10 inches tall and 8 inches across at the base of the element tapering down to about 5 inches at the top. at first I just mounted the filter on top of the snorkle pipe without the cover and baffle and it was extremely loud! when you stepped on the throttle it just roared! I then thought about something I had noticed on my 11hp v twin ingersol rand comercial air compressor when servicing its air filter about a month ago. the filter box on the compressor was a totally sealed unit except for 6 small holes with pieces of tubing welded into them. the tubing was about an inch and a half long and went into the filter housing and I could see no purpose for them at all untill I turned the compressor on with the filter lid off!! it was extremely loud without this cover and the intake noise was cut by about 80% with the cover reinstalled. I wanted to make sure this intake muffler/baffle would flow plent of air so I installed 10 1 inch outside diameter tubes which have a 7/8 inside diameter. it flows WAY more than enough air now and is extremely quiet! now I also dont have to worry about by filter being exposed to dust and sand or even rain and nothing can be more free flow than this setup. its just a shame it looks like a lamp shade....
 
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#4 · (Edited)
Yes sir, i do believe that will fix the dust isssue. Good job. The only thing that i can see to make it better is to skirt down the diamond plate covering so that it overlaps the intake holes. And maybe shorten it a bit to hide it behind the top of your cage so that it would be protected by low lying tree limbs but i guess that depends on the environment that you ride in. I can tell you this, for me, thats a much better setup than a ram air system sucking from the front that i've seen others do. If you look at my avatar, that was a deep mud hole that I traversed. When the front end went in, about four inches up on the windsheild was summurged before the front began to climb out. My stock intake worked because going in created a wake and a hole in the water just long enough to get my front end high. If I would have had the ram air deal,it would have been flooded out and I would have been dead in the water. Share your info and post it other places I love it!!
 
#5 ·
thanks and yes, I will post some pics of the inside tomorrow. we only ride sand here and tree's are pretty scarce. might hit a stray cactus though. I just wanted it up as high as I could get it to keep it up in clean dust free air. anyway, I will pop the lid off in the morning and snap a photo. and the kragen auto parts HID's are awsome! money well spent.
 
#8 ·
its not loud at all. read the paragraph I wrote yesterday explaining about how I made a silencer designed after the intake muffler on my industrial air compressor. oh, I forgot to mention that I weighed my entire intake system including the booot that attaches to the injector and it weighs just over 7 lbs.
 
#12 ·
This thread came back out of the graveyard (2008)!