What is the best way to cut/trim the Bearclaw?

[Willtill]

What is the best way to cut/trim the Bearclaw/Overflow bottle?

I just got my order of K&N's from Flipmeister last week, and if work doesn't bother me too much today (I'm On Call from home) I plan to sequester myself in my 20 degree's Fahrenheit shed; and begin the dismantling of my air intake system; to install the K&N's. (I do have a propane torpedo heater though to take the chill off......)

So... what is the best way to trim up my Bearclaw? I want the K&N's to be visible; and able to breathe unrestricted from under the Bearclaw itself.

I don't want to screw the Bearclaw up, so any tips on the best surgical procedure to follow will be greatly appreciated.


Thanks!

 

[Trirocket3]

I just went at mine with a 4" grinder, worked for ok me, then used plastic chrome edge trim.

 

[xhdskip]

Will,
I took my dremil tool to mine.
used a marker to mark a line about 1/4" below where I wanted the final "real" cut to be,
then cut the lower line first.
This allowed me to get a "feel" for the way the dremil was gonna act on the metal.
Once I had the first "initial" cut made, I preformed surgery with no problem at all.
Did use a piece of the winshield trim on the bottom afterwards.

 

[barbagris]

So... what is the best way to trim up my Bearclaw? !

I'd start by sedating the bear.

TR3 - nice execution.

 

[MountainMan]

Just remember what my dear, old Dad used to say at those critical moments as I stood poised above the task with cuttingtool in hand -

"Whatever you do, don't f#*k it up!

 

[Willtill]

Will,
I took my dremil tool to mine.
used a marker to mark a line about 1/4" below where I wanted the final "real" cut to be,
then cut the lower line first.
This allowed me to get a "feel" for the way the dremil was gonna act on the metal.
Once I had the first "initial" cut made, I preformed surgery with no problem at all.
Did use a piece of the winshield trim on the bottom afterwards.

Think I'll do that, just like you did with the practice cut first. Thanks.

Couple of pic's, just got done gutting the stock intake:



K&N's installed:



I'm pleased at the additional amount of underseat storage I have now. I didn't know the airbox was so huge:

 

[Blastedbones]

-

"Whatever you do, don't f#*k it up!

What he said ! :lol:
Seriously tho... visualise what type of cut you want to end up with( eg from my claw)
outline on the BACK of the claw in permenant marker, use meths to wipe & remark if a mistake. CLAMP the claw carefully. I used a black & decker workmate bench.
Go to it CAREFULLY with a 4" angle grinder using a narrow metal grinding disc.Cut WITHIN the marked line ( ie conservatively) so you can clean the cut using the grinder as a power file. Finish the edges with a hand file & trim.( I used cheap flexable plastic slide on trim & black silicon glue)I saved the off cuts to make chrome tops for the filters.

 

[Willtill]

What he said ! :lol:
Seriously tho... visualise what type of cut you want to end up with( eg from my claw)
outline on the BACK of the claw in permenant marker, use meths to wipe & remark if a mistake. CLAMP the claw carefully. I used a black & decker workmate bench.
Go to it CAREFULLY with a 4" angle grinder using a narrow metal grinding disc.Cut WITHIN the marked line ( ie conservatively) so you can clean the cut using the grinder as a power file. Finish the edges with a hand file & trim.( I used cheap flexable plastic slide on trim & black silicon glue)I saved the off cuts to make chrome tops for the filters.

Roger that!

I'm going to ditch the stock OEM coolant overflow as well, and replace it with one from Summitracing.com. Looking at something like this:



Going to mount it on the left frame sat behind the engine. The bottle should be narrow enough; though I hope 13" length is not too long. I need to go back out and mease that frame stay.

 

[xhdskip]

CRAP Will,
$94.00 for an overflow?
Do what I did, go to Walmart and buy an aluminum water bottle for $10.00
Use you old hoses and a drill bit and save yourself a few bucks.
But then maybe I'm just cheap.
Naw, that can't be it, I just spent $185.00 on headlights,
and haven't even got the bracket started yet...
Haven't decided if I'm gonna cut this clearview windshield and make it work yet or not...

 

[tdragger]

I haven't mounted it yet but this is the bottle that I bought.