[klarowe]

I decided to run to my local pepboys and pick up the necessary parts for the DIY $57 Big Air kit. After cutting up the airbox exactly as the write-up showed and attached the bracket, I have noticed that I have a big problem and I'm not sure if I screwed up or if it is a possible flaw in the original design.

Underneath the throttle body openings are 2 'wings' that go out to the sides. With the airbox cut, these now go direct to atmosphere and bypass the intake. This will allow dirt, debris, etc. to have easy access directly to the motor... which could lead to disaster. Since I was not pretty much screwed, I ended up expediting a Cobra PowerFlo in order to have it by this weekend.

So, did I screw up or is it a possible flaw in the design?

Some pics:

 

[K9Stryker]

Normal, get some jb weld fill in those holes sand/grind it smooth and you good to go

 

[BOOLSHOT]

I left the raised sections on mine, so it did not create those holes. But I agree, use some JB Weld, or some epoxy, and fill them in.

 

[eraser]

Agree with everyone else. JB weld.

 

[klarowe]

I thought about that, but I really didn't feel like trusting my motor to some JB-Weld so I went ahead and ordered a Cobra PowerFlo with expedited shipping to make sure it's ready for when this crap weather goes away.

 

[nakoa01]

Are all the BAKs like this? Just ordered one myself

 

[klarowe]

I would hope not... this was the DIY method for a 'cheap' intake system.

 

[BOOLSHOT]

I was a little nervous about the JB weld and cold steel too. I used a lot on mine. I checked it after several hundred miles, and that stuff is solid as a rock. Bonds really well with the parts. I feel 100% confident it will not come off and hurt motor.

Sent on the run from Tapatalk.. cuz that's how I roll...

 

[klarowe]

Was that ever posted in the DIY thread? I thought I went through that completely to make sure it would go smooth (since I really didn't want to have down time with the bike) but maybe I missed it???