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With a bit more free time on my hands, I've set about improving the air intake system on my Fury R1. I've always wanted to replace the open filter with an air box and remote filter arrangement. The main reason to do this is to reduce the intake noise but the current open air filter doesn't quite fit and is slightly squashed by the bonnet. I'd also like to locate the air intake into a colder air stream, rather than sucking in the warmer air under the bonnet.
With this in mind, I set about designing a new air box to be 3D printed on my new Ender 3 Pro 
3D printer. I'm using Autodesk Fusion 360 to design all the parts.
The first 3D printed test part was a simple plate with holes to check the spacing for the trumpets and the air temperature sensor. This revealed that the temperature sensor needs to be relocated further out.
The second 3D printed test part was to test the height clearance and the new sensor position. I also tested out printing the 5mm holes with M5 threads inside them.
The 3D printed test parts show that I've go the basic dimensions correct and it all fits nicely.
The test parts are 50mm in height and this provides good clearance under the bonnet. With this all looking good, I could now focus on the air inlet.
From my new air box, the plan is to run a 76mm diameter flexible hose to this Pipercross aluminium neck cone filter .
I eventually settled on a design that 3D printed the air box in 3 parts, with interlocking edges, to improve sealing at the joins. The main reason for this was to ensure it could be printed on a wider range of printers. It could be printed in one piece but this would require a very expensive, commercial printer with a large print bed. In three pieces, the largest part is just 180mm × 120mm × 50mm.
Part 1 - The rear section covers two trumpets. I've actually modified this slightly now, to provide a connection for the engine breather pipe.
Part 2 - The middle section also covers two trumpets.
Part 3 - The forward section will cover a 76mm hole in the bottom plate, for the inlet hose and also the air inlet temperature sensor.
Once glued together, these will be sandwiched between two custom aluminium plates (2mm thick), to form a very rigid structure. Twelve 60mm M5 A4 stainless steel bolts will clamp it all together, with washers and nylocs on the underside. All my 3D prints so far have been done using PLA but, this won't withstand the heat well. The final parts are being 3D printed for me by a friend using carbon PETG material in black.
The 2mm thick aluminium plate has been ordered. This will be cut with a jigsaw to get the required shape and finished by filing the edges. It would be nice to get it laser cut.
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