KZ440-A1 Air Filter Holder -- Fabrication Example

So I picked up a 1980 KZ440-A1 LTD that lacked an air filter element or holder. Apparently this is a common problem. So, rather than endlessly trying to tune the carbs for pods, I fabricated new filter holder made of aluminum. I've included steps and plans to help anyone else who might have this issue.

#1: I purchased a 12"x12" sheet of aluminum from Home Depot. You will also need tin snips, some small rivets, 1/8" & 1/4" drill bit, and mounting bolts (2 M6x16)

#2: Here are two links to that are to scale plans for the box. just print it off without scaling and it should fit the box.

This first plan has a 3/8" pocket for filter element. This is good for fitting one layer of UNI foam element, or two oiled '000' synthetic scour pads I'm using until I get my UNI foam.
Plans for 3/8 holder

This second plan has a 3/4" pocket for filter element. This is good for fitting two layers of UNI foam element, say one black one red.
Plans for 3/4 holder

#3: The solid black lines are for cuts. The dotted lines are folds: all short dashed lines should be folded into the page and the one long dashed line folded the other way (out of the page).

I used a hammer over a sharp corner to fold the aluminum bends.

#4: I folded the tabs inside on each of the four corners and tucked them under. I then used a 1/8" drill bit to make the holes for the aluminum rivets.

#5: Three pilot holes were drilled with the 1/4" drill bit in the front face and the tin snips used to open the passages up.

#6: Lastly, the two mounting holes were drilled by placing the holder onto the airbox and locating the proper centers. The centers given on the diagrams are just approximate.

let me know what you guys think. I have some o-rings on order to arrive midweek - after that I can let you know how it operates. Below are some photos, including one with the holder mounted with two oiled scour pads in place.

[img size=(300)] www.davidpurdy.net/Holder/dscf0001.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0002.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0003.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0004.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0005.jpg [/img]

Wow man, nice work!
Very nice of you to contribute the patterns back.

Purdy... this is a most useful post for a KZ440 owner. I would get it to Stein for inclusion in the permanent filebase or tech article section. It will soon get lost here in the carbs section and given the poor search abilities of the forum, may not get into the hands of those that need it otherwise. Good job! wg

I'll throw it together into one PDF file so that it is easier to keep in the filebase.

single PDF version

This is awesome. ive been looking for something like this for a long time. I will have to try it out

Nice work - However... Oiled scour pads...??? :blink:

Fo - get that shit mate. Get some real filtration in there pronto. Use a good car filter. You should be able to find one that fits right in there nicely/or jsut clip it - and wont cost much at all.
If it aint manufactured for air filtration use, dont use it, else you'll be rebuilding that engine in no-time.

2cents.