"Chuckster" plate w/stock cover or open filter

[dkdixie]

When Joe advised he was making a new 7" plate I jumped on it.

I've been wanting to do this mod, but did not want to spend the 200+ bucks for the Thunder kit. Basically, the only difference between Thunder and Chuckster's is Thunder uses an adapter which lowers their plate about an inch. It also sticks out about 3/4" further than stock.

After receiving the Chuckster plate, found out quickly it had to be modified for the stock cover to clear the gas tank. Not a problem with Thunders because of the adapter.

As you can see, the 7" filter has plenty of room when matched up with stock "dog bowls."
But when mounted, have about 1/4" of clearance at the top between filter and cover......and much more everywhere else.



After discussing the tank clearance with Joe, "we" decided to move the mounting holes up 5/8."
After Joe did the drawing, the filter was too far into the throttle opening....so, the though was 1/4" was all we could raise the plate and not interfere with air flow.

New plate shows the addition of the holes for the two vacuum tubes as well as the threaded crankcase vent hose fitting.

I put silicone on the gaskets to help seal the vacuum tubes from the backside as well as slight amount around the throttle opening for the plate to seal against. Slipped a couple vacuum caps on the lines and gave throttle opening and butterfly's a good cleaning.
Add a couple jam nuts to the cover 1/4x20 mounting rod to keep from crushing the filter and that's pretty much it.




As this picture shows, the plate and cover are a little off center but you really have to look to notice. May decide to paint it black which will make it less noticeable.




I believe the bike has never run as good as it does now. Marked improvement in throttle response and it feels like it has more power.
Also, first two tanks were 41.5 and 41.7.

All in all, while not perfect fit, I like it......and that's includes saving 200+ dollars.