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Buell Motorcycle Forum » XBoard » Buell XBoard Archives » Archive through July 07, 2005 » Cutting the airbox (which tool to use?) « Previous Next »

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Bonesbuell
Posted on Tuesday, July 05, 2005 - 12:59 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I'm planning to cut a design in my airbox and would like some recommendations on what tools to use. It's a tribal design that requires some tight lines and points. I'm guessing a dremel saw and very light sand paper for finishing. I'll back it/reinforce with thin lexan or simular and add red LEDs to illuminate from beneith.

tribal design


(Message edited by bonesbuell on July 05, 2005)
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Trojan
Posted on Tuesday, July 05, 2005 - 04:17 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

A 5lb hammer should do the trick then.....
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M1combat
Posted on Tuesday, July 05, 2005 - 06:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I used a dremel and a "rotozip" type bit to cut my INNER airbox cover...
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Tatsu
Posted on Tuesday, July 05, 2005 - 07:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I would get another lid and practice on it first. Once you start cutting you can't fix it if you mess up. That would actually make a cool belt guard, if you could find some material large enough to cut on.

(Message edited by Tatsu on July 05, 2005)
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Jaredkuper
Posted on Tuesday, July 05, 2005 - 11:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

What about sawing it with a guitar cord or some other cable? Not sure if it'll work, but might be worth a shot to experiment.

I tried to use a dremel bit on the inner cover, but ended up switching to a hacksaw blade and then a very small circular blade on the dremel. None of it looked like it would do too well with details though.

Good luck!
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Buelltroll
Posted on Tuesday, July 05, 2005 - 11:34 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

A stencil and a heatknife?
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Buellj79
Posted on Tuesday, July 05, 2005 - 11:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

i used a dremel, just watch out for the molten plastic
later J
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Xbolt12
Posted on Wednesday, July 06, 2005 - 12:08 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

And watch out for your finger if you use the 3/8 dremel saw blade-verrry dangerous tool. I had to superglue my finger back together after a slip while cutting my airbox lol
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Knotrider
Posted on Wednesday, July 06, 2005 - 01:14 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

seems like alot of work. have you thought about getting a few stickers instead?
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Ronlv
Posted on Wednesday, July 06, 2005 - 01:41 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

i thought about taping off a tribal design on a cityx airbox and painting the rest, then peel the tape and the tribal design will be clear blue and then could be back lit
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U4euh
Posted on Wednesday, July 06, 2005 - 01:53 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Dremel with the metalcarbide bit, and a router attachement. Like Buellj79 said, watch out for molten plastic. If you decide to go this route, lay down masking tape so the router attachment doesn't scratch your plastic.

I also put the blue LED's under the lid. Just check run'em on the street till you know if it is ok w/the law.
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Henrik
Posted on Wednesday, July 06, 2005 - 08:36 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

A coping saw, fine tooth files, fine sand paper glued to small paint stir sticks or popsickle sticks - and lots'n lots of patience ...

Henrik
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Buellboy05
Posted on Wednesday, July 06, 2005 - 09:22 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I would use a machine gun but thats just me
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Onebuell
Posted on Wednesday, July 06, 2005 - 10:33 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

why r u going to hillbillify it?

just buy that 12 cover.

which im trying to snag the OEM part number for
so i can do magic on finding one for less.

hint hint
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Blublak
Posted on Wednesday, July 06, 2005 - 10:50 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Hey Phil, (Buellboy05)... Which one? What caliber?

I was thinking, for the larger sections, an M4? Then maybe a MAC-11/9 for the scroll work and an AM-180 for the finish work?

hehehehehe.. what'cha think?
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Bonesbuell
Posted on Wednesday, July 06, 2005 - 11:47 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I think that's the way to go ronlv, I'll purchase the cityx airbox and paint all but the tribal. TNX

RONLV Wrote:i thought about taping off a tribal design on a cityx airbox and painting the rest, then peel the tape and the tribal design will be clear blue and then could be back lit
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Ronlv
Posted on Wednesday, July 06, 2005 - 06:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

bones,

glad you liked the idea

lets see it when you finish it
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Bbstacker
Posted on Wednesday, July 06, 2005 - 11:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Hey, Buellboy. Go big or go home. .50 cal BMG or nothing.
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