highpocket74
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This project has turned into my second most successful product design in only 1 month. It all started with the idea to design a simple to install intake tube that didn't look homemade. My first design was to use the passenger side intake grate as passage for the tube. Although this was successful, replicating the design proved to be very challenging. There were many tubing bends required as well as replacement parts for the OEM plastic grate to close the opening around the tube. After building two of these I decided this was not very practical.
As much as I didn't want to cut my factory plastic for a tube installation, I figured I'd have to in order to develop the parts anyway. This turned out to be a good decision! The design idea came to me rather quickly but building the first few versions was a tough puzzle. I wanted the tube to penetrate the fender at a specific location that only required cutting one piece of plastic. That location was determined and the challenge was set as I had to figure the compound angles to get the tube from the air box inlet to the fender location with the simplest construction and allowing the inner fender to still be used.
The end result after much measuring, marking, cutting and welding was this.
The first good version is still running on my machine. After I was satisfied with the design, I then had to figure out jigs to replicate the parts required. I'm completely new to manufacturing practices so I'm no jigging expert. The cover plate was not too bad. I knew I wanted it laser cut and cnc bent for a perfect fit. The tube was a bit tough to build a jig for to get the clocking correct of the compound angles. But the whole assembly was the real task! That jig took some time to build correctly. In fact the first 5 tubes I built with the jig were test fit on my machine to verify a consistent fit. It worked! I'm still using that jig also to produce the finished product design.
After my successful prototype built I did some Arkansas ride testing with friends and the intake kit. We spent a weekend of riding the Wolfpen and Fourche Mountain trails. One of the guys had a brand new stock Talon. After riding 200 miles that weekend we compared air filters and these are the results.
Talon with no pre-filter versus Talon with pre-filter.
My pre-filter setup proved itself the first ride out! For an entire weekend we rode the same trails in the same conditions, often running 7th and 8th positions in the group but never out front. My front
I knew the question would come up about creating air restrictions with a second filter. The PPEI guys in Lake Charles were kind enough to test my Talon on their dyno. After 15 pulls on the dyno, 5 to warm up the Talon, 5 with the Deertcraft pre-filter and 5 without, the dyno showed no loss in performance. That translated into less than 1/10th horsepower difference between the runs.
Now that I had real data I knew I could sell these kits.
Desertcraft has been an excellent partner to work with for these filters. They are always helpful and make top notch US made products. I've been a dealer for almost three years and have NEVER had an issue with them. That is why I have chosen them to be my sole filter provider. They are a small California business, husband and wife owned since 1994. Terrific people and products.
As much as I didn't want to cut my factory plastic for a tube installation, I figured I'd have to in order to develop the parts anyway. This turned out to be a good decision! The design idea came to me rather quickly but building the first few versions was a tough puzzle. I wanted the tube to penetrate the fender at a specific location that only required cutting one piece of plastic. That location was determined and the challenge was set as I had to figure the compound angles to get the tube from the air box inlet to the fender location with the simplest construction and allowing the inner fender to still be used.
The end result after much measuring, marking, cutting and welding was this.
The first good version is still running on my machine. After I was satisfied with the design, I then had to figure out jigs to replicate the parts required. I'm completely new to manufacturing practices so I'm no jigging expert. The cover plate was not too bad. I knew I wanted it laser cut and cnc bent for a perfect fit. The tube was a bit tough to build a jig for to get the clocking correct of the compound angles. But the whole assembly was the real task! That jig took some time to build correctly. In fact the first 5 tubes I built with the jig were test fit on my machine to verify a consistent fit. It worked! I'm still using that jig also to produce the finished product design.
After my successful prototype built I did some Arkansas ride testing with friends and the intake kit. We spent a weekend of riding the Wolfpen and Fourche Mountain trails. One of the guys had a brand new stock Talon. After riding 200 miles that weekend we compared air filters and these are the results.
Talon with no pre-filter versus Talon with pre-filter.
My pre-filter setup proved itself the first ride out! For an entire weekend we rode the same trails in the same conditions, often running 7th and 8th positions in the group but never out front. My front
I knew the question would come up about creating air restrictions with a second filter. The PPEI guys in Lake Charles were kind enough to test my Talon on their dyno. After 15 pulls on the dyno, 5 to warm up the Talon, 5 with the Deertcraft pre-filter and 5 without, the dyno showed no loss in performance. That translated into less than 1/10th horsepower difference between the runs.
Now that I had real data I knew I could sell these kits.
Desertcraft has been an excellent partner to work with for these filters. They are always helpful and make top notch US made products. I've been a dealer for almost three years and have NEVER had an issue with them. That is why I have chosen them to be my sole filter provider. They are a small California business, husband and wife owned since 1994. Terrific people and products.
