SV650 - Air Duct Design Part 2

Back to the air ducts - now popped off the molds and roughly trimmed (they even look symmetrical).

With the fibreglass parts roughly trimmed, they can be "fine tuned" and fitted together as seen above. We have designed them to have the smooth (molded) surface of the part on the inside of the duct and the rougher, fibreglass mat material on the outside, as this will be how the airbox will be laid up. (The performance of the air is more important then then aesthetic of the part when hidden in the engine!). That said, we have confidence of achieving a nice external appearance to the ducts.

Test fitting to the bike and working out where mounting points will be. There are a few modifications to make to make the fitting easier, as can be seen above with the duct sitting on the mold.

These pictures show the position of the air duct. Its a very snug fit to get the maximium air volume through the steel trellis frame, as we did look at various options of taking it back further and entering through the side (like Ducati) but this gave us the wrong position for the air filter we intend to use. 

In hindsight, a little more thought on some of these later aspects earlier in the design would have been beneficial, but we are always learning . . .

Next time, airbox entry and final molds . . .