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Making a DT400 air box cover

  • DT Tim
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Making a DT400 air box cover was created by DT Tim

My DT400 came without the right side, black plastic air box cover. Finding one was like rocking horse poop, and when I did see a pair, I decided to keep hold of my kidney.
Having experience in the automotive industry and GRP I had an attempt at making a replacement. First off create the mould out of wood, check dimensions, then cover in masking tape.

  

Apply the glass fibre….

  

When cured and because of the tape and shape, it was easy to separate from the mould.

 

 
28 Aug 2021 08:42 #1

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Replied by DT Tim on topic Making a DT400 air box cover

Then I offered up the cover and trimmed with a orbital sander.

 

Then sanded the surface to a reasonable finish and applied a flexible filler, like the stuff used to repair plastic bumpers.

 

That was flatted, and then a little filler primer and a top coat of satin black.

  



 
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28 Aug 2021 08:47 #2

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Replied by DT Tim on topic Making a DT400 air box cover

I’m fairly pleased with the outcome but when time allows I think a MK 2 version will be produced. Maybe paint gloss black and the surface will be concave too.

 
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28 Aug 2021 08:49 #3

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Replied by MarkT on topic Making a DT400 air box cover

Wow! 

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I'm impressed.  Fantastic job! 

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1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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28 Aug 2021 08:52 #4

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Replied by Gr8uncleal on topic Making a DT400 air box cover

Great work Tim. 

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Another theoretical alternative would be to 3D print one (someone here in the UK has made some RD250/350 airbox lids).
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28 Aug 2021 14:08 #5

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Replied by Grussell on topic Making a DT400 air box cover

Looks good. That takes talent!
1978 DT400
1975 DT250
1976 YZ125X - my post vintage race bike
2022 KTM 300XCW - my race bike

28 Aug 2021 15:27 #6

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Replied by Ht1kid on topic Making a DT400 air box cover

Excellent Job!!!
28 Aug 2021 15:42 #7

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