Duke 4 complete airbox delete project, success! - KTM Forums: KTM Motorcycle Forum
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post #1 of 235 (permalink) Old 04-09-2016, 02:46 AM Thread Starter
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Duke 4 complete airbox delete project, success!

Hey all,

I thought I'd start a thread about the mod I have been working on, mostly to get people's thoughts and feedback.

After taking the airbox out to do a SAS/Charcoal delete I realized what a huge and heavy unit it is, so I thought I'd see if I could follow in the SMC guys' footsteps and come up with a way to delete the airbox altogether and fit a pod filter.

I doubt there is any power to be gained from this, as the stock box is tuned for the motor and flows tons of air. It was just for fun, and because I think the bike looks real nice with open air where the airbox used to be.

One issue was that the stock rubber intake runner that goes from the airbox to the throttle body actually projects inside the airbox and trumpets out. The trumpet (velocity stack) helps smooth the air and increase its velocity, and the length of the runner is important as well, as it is tuned to work with intake air pulses (shorter runner=high rpm gains; longer runner=low rpm gains). I wasn't willing to lose the tuned nature of that runner, so I designed and 3D printed a velocity stack that keeps the same length and trumpet profile, but actually slightly enlarges the trumpet outer diameter for more air smoothing.

Here's the piece:

[IMG][/IMG]

[IMG][/IMG]

Unfortunately I don't have any pics yet of the bike fully put back together yet (still working on other mods), But here's some with it mocked up on the bike:



[IMG][/IMG]

[IMG][/IMG]



Anyway, that's about it. I'm pretty excited to get it all back together and start blasting around!
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Last edited by Kafka; 04-09-2016 at 02:52 AM.
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post #2 of 235 (permalink) Old 04-09-2016, 11:31 AM
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Nice work. Whats even heavier is the silver subframe. I removed it to paint it black and it is heavy. Would be nice to replace it with something else. Probably could lose 20lbs with an alternative simple designed unit.

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post #3 of 235 (permalink) Old 04-09-2016, 12:53 PM Thread Starter
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^^ It's heavy and ugly, Bill!
I'd love to do a custom tubular subframe, but it'd be a bunch of work.
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post #4 of 235 (permalink) Old 04-09-2016, 05:43 PM
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When do these start shipping?! 😉


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post #5 of 235 (permalink) Old 04-09-2016, 11:23 PM Thread Starter
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^^ I still have to weld up a small bracket to go from the end of the filter to the subframe bolt right in front of where the seat mounts to the subframe. It would probably be ok without it, but I feel like it will secure the whole thing in place really nicely.

I could make them available to people as kits, but it doesn't seem like there's much interest judging from the lack of comments here.
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post #6 of 235 (permalink) Old 04-10-2016, 04:00 AM
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I could start with som input.. i would like to se a solution with the podfilter tilted downwards. We could then make a huge storage space

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post #7 of 235 (permalink) Old 04-10-2016, 04:59 AM Thread Starter
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Sure, man, I'll her right on that. 😊

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post #8 of 235 (permalink) Old 04-10-2016, 05:14 AM
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I'm in for one subframe and pod kit. I'll have an Orange seat with carbon-grey piping please.

No - seriously - depending on $$$, I am in.
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post #9 of 235 (permalink) Old 04-10-2016, 08:11 AM
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did the sound change?
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post #10 of 235 (permalink) Old 04-10-2016, 05:44 PM Thread Starter
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Right on. I'd be happy to make a kit available to whomever wants one.

Here's where I'm at now: I need to design and make the bracket, put it all together, then run it a bit to check it out. After that, I'll post back here, or make a new post, offering the kit.



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