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Have you researched what material will be suitable? The plastic will need to withstand heat, fuel, vibration & shock. Someone tried using an ABS project box from Radio Shack on a 440, but the plastic didn't hold up. It was a nifty idea that just didn't work. He then made an airbox from an aluminum box off of Amazon.com. KZ440 airbox

I let the 3D printing people know what it was being used for, and I asked them to recommend a material based on the heat, vibrations, etc. I saw that KZ440 airbox you're talking about, and I'm thinking that would probably be a much easier and cheaper route. All you have to do is make sure the air inlet is 2 sq in. I think I'll try that idea first. It would create a space under the seat for storage and cut down on weight a little. Definitely worth a try.

I don't know much about 3D printing. There are small nylon or polyester carb parts that probably would be good candidates for the process, but just in case you decide to go ahead with the 3D, I'd check to see if any large parts have been proven to work in automotive or motorcycle applications before moving forward.

Has anyone figured out the whole 3D printing idea for one of these cap, air filter boxes?? I am in need of one and like everyone else on this forum and probably all over the world I can't seem to find one ANYWHERE... I saw one on ebay a while back but sadly wasn't fast enough to buy it and got beat to the punch..

No eBay APP ID and/or Cert ID defined in Kunena configurationThere is one on ebay, a miracle I would say.


As for 3d printing there has to be a financial incentive for this to happen, like there are 100 people who will pay $500 for one, the chances of that are zero.