air filter assembly

Air Filter Assembly

-  the engine started with 75MM velocity stacks with SS screens only.  These are rather restrictive and do no filtering.  The particle size on the screens is 140 micros while typical dust is 20 to 30 microns.  So there is little to no filtration of dust, bugs or rain.

While this may look cool it is not very effective and keeping the dirt out of the engine.  The chokes were wide open to the atmosphere.  

I went with ITG Sausage filter from Daemon-Tweeks with an aluminum blank mounting plate.

Step 1 was to cut down the velocity stacks from 75mm to 47mm.  cut holes for the throttle bodies, chokes and velocity stack mounts.  This left very little room for the filter to fit.   After trial and error the only way to fit was to install the 3rd velocity stack (from the firewall) first.  Then insert the stack for the front cylinder and mount it.  This was followed by the rear two velocity stacks.   

The completed project provides filtration and quietened the intake sounds slightly.  

Lexan Doors

Lexan Doors

After advice from the Internet and Industrial Plastics, I went with 3mm  M10 - Lexan.  This is the version with the Antiscratch coating.

-  I removed the metal frame from the original doors. and attached a cardboard cutout of the door.  This allowed for adjustments and tight fit to the new door opening.

Once I was happy with the fit I used the cardboard as a template to transfer to the Lexan sheet.

The next step was to cut the Lexan.  I choose to use the scroll saw for this and while it did do the job with the new plastics blade is was difficult to control and shape the corners.  For the second door, I used the Bosch Jigsaw with the Plastics blade.

This made for very easy and controlled cuts, corners and shaping.  The edges were cleaned up on the belt sander.  the final edge sanding was done with a hand file and 400grit paper.

I next attached the metal frame from the original door to the Lexan.  All holes were drilled with cobalt drill bits and a slow and steady drill made perfect holes.

Blind nuts were used to connect the two together.  A strap with snap for a door latch and I was on the road.

The added length of the door eliminates the buffeting from the sides.  Even at highway speeds, the buffeting is negligible. 

To test this I removed the doors and went for a blat around the block onto the highway. I got up to 60 MPH and the wind and vortex tried to suck the toque right off my head.  This is the standard effect of a doorless 7 on the highway.  

Test 2 was to put the wind wings on and go for another loop.  While this was better and my hat stayed on my head is was less than comfortable at speed.

The final test was with the doors for the same loop.  Wow, what a difference.  Virtually eliminated the buffeting and I was able to have a conversation with the passenger.  

provincial inspection

Inspection at Ian Tait Mechanical

- Professional service at a reasonable price

- minor repair to a headlight and i was on my way with an inspection sticker