|Project by qball||posted 01-12-2012 09:38 PM||1800 views||0 times favorited||6 comments|
I was asked by a buddy that saw some of my work if I could make an air filter cover out of wood to replace the stock chrome cover on his bike now. I jumped at the idea even though this is something that is nowhere near anything I have tried before.
I received the cover along with the air filter cover a few days later and began looking over it and quickly learned that this want going to be as easy as I hoped. The back side had 2 different sets of grooves that held the air filter in. Well I sat on it a few days thinking about how I was going to make this happen. It came to me to trace the inside groove along with the bolt holes and then create a template from this to start with. This template would allow me to use a flush trim bit set at 1/8” to create the inside groove. No problem here. So I grabbed a piece of old poplar with some nice character and went to work on the prototype. (Pic 2 & 3) I used 3/16” dowel in the bolt hole locations to keep the template in place on the work piece.
I then had to come up with a way to create the outside groove. After a lot of math I found that a ½” straight bit with a 5/8” could create this groove if I could offset the original template 1/8”. I came up with a simple solution to create this offset template, a 5 cent flat washer. I found a washer at the corner store that had a 1/8” difference between the inside and outside diameter and used it to trace the original template and then rough cut and sanded template 2 down to the 1/8” offset line. Then I attached it to the work piece and routed the ½” wide 3/16” deep groove. Again I used 3/16” dowel in the bolt hole locations to keep the template in same place for tracing the template & routing the work piece. (Pic 4 & 5)
Now for the home stretch I attached the original cover to the work piece with the original mounting screws and traced the final shape of the piece. I then rough cut and sanded the work piece to the final shape and added a 45 degree chamfer to match the original. (Pic 6)
After it was all said and done the air filter fit was a little tighter that I would have liked it to have been so I decided to make another prototype free of charge just to get the fit perfect. (mostly personal satisfaction) I originally used a pencil to tract the washer mentioned above to get the offset. I decided to use a marker this time to get a little bit more of an offset. I then sanded down to the outside of the markers line to get my new template. I went through the hole process again with a piece of western cedar that I added a strip of redheart to give liven up the piece and ended up with my second prototype. The fit on the second one is as close as you can get to perfect.
I hope that the client doesn’t decide to just keep one of these on his bike. He was originally wanting to make it from something more dense so now that I have the templates dialed in I’m ready to knock out more. Anyone have any recommendations for a durable material & finish for this piece? Something that can hold up to heat as well as rain.