"NEW" Chuckster backing plate (Update Pg 6)

[dkdixie]

Ok, may be a dumb question, outside of "dirty" air, what's the pro & cons of adding filter to the gas vent line?

[ponch]

I would think that you'd need a better flowing exhaust to get the most out of a modified air intake. do you use an ECU spoofer or the resister mod? It'd be interesting if you had access to dyno to know before and after each mod. how about gas mileage?

[cactusjack]

I thought that it was a crankcase breather tube. Are you saying that is the return line for the EGR canister? Boy, do I feel dumb. Actually, I will probably drill and tap the backing plate and install an appropriate fitting to vent the line back into the intake.

[cactusjack]

Originally Posted by ponch

I would think that you'd need a better flowing exhaust to get the most out of a modified air intake. do you use an ECU spoofer or the resister mod? It'd be interesting if you had access to dyno to know before and after each mod. how about gas mileage?

Yeah, you're probably right. I'll most likely get one someday. My gas mileage averages just under 37MPG. I have a Cobra FI2000R, these mods were done more to prevent chronic pinging than to make it go faster. It's all-black, so it's inherently faster than other Nomads.

[mikesth]

got all my stuff ordered - moving into a new century *rubbing hands anxiously*

Thanks Joe!

[dkdixie]

Originally Posted by cactusjack

I thought that it was a crankcase breather tube. Are you saying that is the return line for the EGR canister? Boy, do I feel dumb. Actually, I will probably drill and tap the backing plate and install an appropriate fitting to vent the line back into the intake.

Hang in there CJ....according to KAW manual it is a crankcase breather line. Have not had the stock plate off yet, still waiting on filter, but it looks like the line connects to "L" connector into stock plate.
Anybody see anything wrong with drilling hole and using same "L" connector as press fit or epoxy in? Being inside the filter would make it a filtered line.

[cactusjack]

Originally Posted by "dk dixie"

Hang in there CJ....according to KAW manual it is a crankcase breather line. Have not had the stock plate off yet, still waiting on filter, but it looks like the line connects to "L" connector into stock plate.
Anybody see anything wrong with drilling hole and using same "L" connector as press fit or epoxy in? Being inside the filter would make it a filtered line.

I would just drill the aluminum plate and thread it with a pipe thread tap, then install a 90 degree elbow and then screw a 3/8" barbed brass fitting into that, then just slip the hose on.

I didn't think it was just a fuel vapor return because you can feel air pressure pulsing through the hose with the engine when it's running.

[borto1990]

Hey, are some of you chuckster plate pioneers takin good pics of the install process? I'm hoping to get all my stuff this week and would love to get my peepers on your full parts list ect.

[dkdixie]

If you are planning on purchasing Chuckster plate AND plan on using stock covers, you will have to do one least one modification. That is drill mounting hole (and tap 1/4-20 if you want) for the cover rod.
The plate in designed to be used with exposed filter, and I'm sure it works fine, but I wanted to use stock covers....so, drilled hole 5/8" below existing mounting hole to give clearance for the gas tank. With existing mounting hole the tank will hit the stock cover.

Also, the two center located vacuum tubes can be pushed back and off to the right side but I think CJ's idea of removing and capping off at manifold is a better way to go.

I elected, for the present time, to pull the crankcase breather line up between the two cylinders, cut off about 15 or so inches, rerouted over to the left side and installed external small filter behind the horn mounting bracket.
Next time I'm by a Harley dealer, will purchase one of their small breather filters which are only about an inch or so long. Or, I'll let CJ tell me what size tap and drill to use and thread the bottom of the plate.

[cactusjack]

Originally Posted by "dk dixie"

If you are planning on purchasing Chuckster plate AND plan on using stock covers, you will have to do one least one modification. That is drill mounting hole (and tap 1/4-20 if you want) for the cover rod.
The plate in designed to be used with exposed filter, and I'm sure it works fine, but I wanted to use stock covers....so, drilled hole 5/8" below existing mounting hole to give clearance for the gas tank. With existing mounting hole the cover will hit the tank.

Also, the two center located vacuum tubes can be pushed back and off to the right side but I think CJ's idea of removing and capping off at manifold is a better way to go.

I elected, for the present time, to pull the crankcase breather line up between the two cylinders, cut off about 15 or so inches, rerouted over to the left side and installed external small filter behind the horn mounting bracket.
Next time I'm by a Harley dealer, will purchase one of their small breather filters which are only about an inch or so long. Or, I'll let CJ tell me what size tap and drill to use and thread the bottom of the plate.

I have to admit I didn't realize the 2 vacuum tubes were mounted on a rubber mount that could be slid off the hanger. Had I known that, I probably would have just pushed them back out of the way. I removed the hoses at the manifold instead. The end result is the same, but it will be much trickier to reconnect the hoses at the manifold if I ever need to put things back the way they were. I don't necessarily foresee having to do that, but you never know.

We learn as we go here, folks. One of the responsibilities of being an "early adopter" is you get to post about your experiences (good and bad) so others may learn from your successes and failures.

[blowndodge]

Your such a good sacrificial lamb CJ

[voyager]

Hey CJ,

You did the right thing by removing the vacuum lines all the way to the intake, because the rubber hanger bracket that the two lines hang off of act as an anchor against the stock backing plate. If you remove the tubes from the hanger, there won't be any resistance to push the tubes backwards when you install Chuckster's or any after market adapter. This could cause a leak into the intake that would bypass your filter........

voyager

[cactusjack]

I know that ultimately, removing the hoses from the manifold is the proper way to do it. It's just more difficult to return back to stock form. There's not a lot of room to work around the manifold. I'm happy with the way it turned out. Now I need to figure out what to do with the LH side.

[dogdoc]

i ran a new crankcase breather hose to the right side engine guard top bolt. Drilled out the bracket hole a little larger and the bolt goes right thur and tightens up well. i bought a chromed out filter about 2 inches dia from dennis kirk/w bracket(chromed) for like $20. Looks good on that side and gets good airflow.

[dkdixie]

GOOD NEWS from Chuckster!

Just talked with Joe and he is going to do some redesigning on the backing plate.

First, he's going to offer two options, one using stock covers and the other, using exposed filter.

Secondly, he going to drill two holes for the vacuum lines. All user will have to do is run a bead of silicone around them on the plate. The existing little rubber grommets will help seal from the backside.

Third, he's going to look into drilling and tapping hole for the crankcase vent line. Will not be suppling the fittings but will tell you what you need if you want to go this route.

So, if you are looking to purchase you may want to call him or specify in an e-mail exactly how you plan to use the plate and what you want as options.

Joe thought he would have the updated versions ready in a week or so.....