'77 - '80 KZ1000 Airbox silencer tubes

Be my valentine?

I've got someone printing them locally from ABS for $8/piece. I'll post back here with the results.

I had to post the model to thingiverse in order to share with the printer guy. Hope that's okay DOHC. www.thingiverse.com/thing:4762524

That’s really cool.

Kaylinator wrote: Hope that's okay DOHC.

It's all good. As I said, it's already publicly viewable on OnShape.

Good luck.

Silencer tubes came out great! The printer didn't have any black ABS, so I elected for silver, knowing I'd most likely be sanding and painting them anyway to clean them up. I'll report back with fitment when it's warm enough to spend some time in the shop.

Cool. I like the silver. The inlet radius looks a bit wonky. Is that just a trick of the light?

Have you test fit them into the silencer housing yet?

How strong do they feel? Does it seem like they will hold up?

You may have your own CAD model by now, but if not I'd be happy to beef up the wall thickness and send an updated file. Given that they are cheap to print, it might make sense to get a heavier set to play with.

I haven't test fit them yet. Just picked them up this evening, but I'll report back once I've checked fitment.

They feel VERY strong. I can squeeze quite hard without any flex. If it fits, I can't see why these wouldn't work. It appears he printed them in quite a high resolution.

The inlet radius ended being less of a radius and more of a 45. I imagine that's just a limitation of the printer. There's more than enough material there that I can sand it to a nice radius, although as I'm typing this, I'm wondering how well a trim router would work the make that radius perfect.

Those look nice. I like the trim router idea. Maybe an 1/8” round over with a bearing follower. I’d drill a hole in a piece of 1x6 and drop the tube in. Les chance of the router tipping and cutting through the side.

Next up is a1976 KZ900 air box... lol

Funny you say that. I was actually thinking that if we created a bunch of 3D models of highly sought after airboxes and had them printed, they could be sold on eBay for a reasonable sum, with all proceeds funding this great forum.

Popped out to the shop quickly this afternoon. The silencer tubes are a perfect fit, and a 1/4" round seems to have been just about perfect. Went just the tiniest bit too deep with the router, as can be seen in the first photo, but a bit of sandpaper took care of that in a hurry.

Kaylinator wrote: Funny you say that. I was actually thinking that if we created a bunch of 3D models of highly sought after airboxes and had them printed, they could be sold on eBay for a reasonable sum, with all proceeds funding this great forum.

I like it... functional but not for the purest... proceeds to the forum is awesome

I'm assuming you don't have the original screws. I'm also missing one, so I thought I'd look around. It's an odd size. My guess is that it's a screw intended for plastic, probably thread forming.

Here are my measurements:
screw thread OD: 2.88mm
thread Pitch: 1.0 (this is approximate, it's tough to measure)
screw length: 7.4mn
Head diameter: 7 93mm

Looking at McMaster-Carr for "Thread-Forming Screws for Plastic", they list M2.63 and M3 sizes, with thread pitch of 1.06 and 1.12mm.

www.mcmaster.com/99397A351/
www.mcmaster.com/96817A908/

If you could figure out where to buy these, you could probably find one that matches pretty closely.

stanleyind.com/wp-content/uploads/2018/0...ltaBrochureFinal.pdf

EDIT: I would probably go with the M3 as it's slightly larger than the OE screw, and should reform the threads in the silencer body since it's thread forming.

Also, the screw shown below has been painted black by the PO. They normally have a slightly gold colored plating as you can see in Mikaw's earlier post.