Plunger frame Airbox - possible production

[Richard A]

Hi,
Sorry for delay in response, but yes if its possible to provide measurements that would be fantastic as any help would be appreciated.
At present I have the wrong box in place which doesn't match and carb is unable to either attach the rubber shroud or Amal supplied alloy rim.

Many thanks for the help offered.

Richard
PS based in Norfolk

[Richard A]

Folks,

I've been very fortunate in that one member of this forum has very kindly spent a lot of time and effort in giving me lots of photos and measurements for both the box and filter. Hopefully this will be enough to enable my friendly neighbourhood engineer to create a new one for me.

I'll update you on progress when I get more info. Might be worth asking him to make 2-3 as sure they'll be well received!

Regards

Richard

[Rex]

If you're running an informal tally of possible customers, then please count me in too. Thanks!

[oldbikerbill]

Could you publish the photos and measurements here?

[a]

-We have a complete used one here https://mikesclassiccyclespares.com/product/67-4594/
Also have a spare used element https://mikesclassiccyclespares.com/product/67-4600/
and have the strap for the battery carrier that I am about to list now 29-4657

[Gavin]

Thanks Mike, Bought it.

[a]

Yeah I didn't think that would last too long

[Richard A]

Hi,

Frustration indeed.
After one of you kind gents provided  me with detail drawings and photos of the airbox I was more than hopeful that someone would fabricate the airbag for me.
I have now tried several fabrication firms to be told they can only work to duplicate an existing one, or need 3D drawings. Neither of which I have.
I guess the search to various jumble sales will now have to continue in the New Year.

Richard

[Greybeard]

I'm very pleased that my bike still had those bits on it. I just needed to buy the shiny battery strap and bolt arrangement.


I can imagine someone using a good filter case to make a mould to then create new GRP filter cases. The other parts could be fabricated from flat stock.

[Gavin]

Hi Richard, I am about 8 weeks off retiring, and plan to tinker on a few bikes I have in the shed as 2018 unfolds. Since starting this post I have acquired 2 more airboxes, and before anyone starts salivating, they are both accounted for on next years projects.

However, I would be prepared to try and make another from fibreglass etc. I will mess about for a while, and if I convince myself it's strong enough to support a battery I will try one the Plungers I am rebuilding, and see how it goes.

Meanwhile all the best at the jumble sales. I'll also keep an eye out in Aus if one appears here.

Have a safe n significant Christmas mate. 

[Greybeard]

...I would be prepared to try and make another from fibreglass etc. I will mess about for a while, and if I convince myself it's strong enough to support a battery...

Good job! As there will have to be a metal bracket for the battery the fibreglass part may not have to carry much weight. As I see it, (from memory) the tricky bits will be setting a threaded boss in the corner for frame attachment and the inner part, where the rubber hose goes.

If these rare things can be manufactured I reckon they will be in demand.

[Sluggo]

I can get them made, But there is a catch,.  While Its admirable someone made drawings, and diagrams, in reality in manufacturing its often "open to interpretation" so only a Print in solidworks, or similar CAD files are worthwhile.   
But *IF* someone can locate a friendly associate who has access to a 3D scanner then along WITH drawings, pictures and diagrams then you can get something accurately replicated.

Not everyone still uses Solidworks, and tech has marched on, but its still a industry standard, If you have other software, let me know and likely I can work with it.

I DO have access to the manufacturing to make these,  If you guys want to move fwd, PM me.  (I have some  other bits in the works)

[Richard A]

Guys,

Thanks for the offers/suggestions, its much appreciated.
At present I've not yet been able to find anyone who can do me a 3D drawing, but will keep looking locally and as I understand then standardworks is the application.
Im still looking for the airbox, but I continue with no success. Hope to visit a few bike jumbles in the early part of the year so my fingers remain crossed.

Regards

Richard

[Richard A]

Sorry,

should have been  Solidworks, not Standardworks.

Richard

[vinver]

I have a spare rigid frame airbox- for early A7. Is it significantly different from the plunger airbox? And, do they use the same filter element, as I don't have one of those, was planning to make one as others suffested.