GL1200 Custom Air Intake


Once the frame was modified and a center spline was put in place to mount the Harley gas tank, the plastic OEM plate that covered the stock air box and held the stock air cleaner was clearly not going to work.  First of all, it was just plain ugly.  Second, the stock air cleaner would hit the new gas tank.  I decided to fab something that would not only function better but also look good in the process.

I took some cardboard and traced out the stock air box plate and transferred the outline onto a section of street sign I salvaged from the dump.  It took some serious elbow grease and aircraft stripper to get the sticker portion off the sign.  From there, it was a ton more elbow grease to get the correct shape and then to polish the aluminum to the level I wanted.  I’m not really into the mirror finish so stopped at slightly more than a brushed aluminum finish.

I don’t have a fancy plasma cutter yet so the outline was rough cut with a sawzall and then refined using a cut-off air grinder.  All in all I’m pretty stoked at how it turned out.

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