How to Build a Carburetor Box

A carburetor box provides surrounding protection for a carburetor that may be fairly exposed to the elements and road dirt. This sort of exposure tends to occur more frequently with smaller vehicles such as motorcycles and scooters than with cars. Making one can be performed using fiberglass. However, the unit needs to be placed in an area where it wont be overly exposed to heat. This tends to be somewhat difficult when carburetors have to be attached to the intake valve. That said, once the location is figured out, the design simply involves a matter of drawing the box and molding it.

Instructions

1

Plan out where you need the carburetor box to be installed on the vehicle. Use a measuring tape to determine the dimensions of the soon-to-be box. Write the statistics down on a notepad with a pen. Draw the carburetor box design on a new piece of notepad paper. Check the final dimensions just to be sure they are correct.

2

Obtain blocks of durable foam. Glue the foam blocks together until the mass is bigger than the carburetor box you need. Cut into the foam with a cutting tool and carve out the shape of the mold you want per your notepad design. Continue cutting and shaving the foam until you have an internal shape that matches your design.

3

Spray the inside of the foam with a non-adhesive wax spray. Cover the surface of the foam mold but dont overdo it.

4

Cut a piece of fiberglass cloth into squares about the size of your hand so you can manipulate them easily. Place them in a pile next to the foam mold.

5

Put on plastic gloves. Mix resin and hardener in a bucket with a mixing stick. Apply a layer of resin with a paintbrush to the inside of the foam mold. Cover the foam surface thoroughly. Pick up pieces of the fiberglass cloth and press it into the resin. Roll it flat with the paint roller. Apply another layer of resin when finished.

6

Continue the process of resin and cloth until the layering gets to be about 20 millimeters thick. Cover the final layer of cloth with another coat of resin. Let the fiberglass cure and dry.

7

Wait a day for the fiberglass box to dry. Pry it loose from the mold with a plastic spreader. Remove the foam mold and throw it away. Trim the excess cloth edges with a pair of good scissors.

8

Put on a respirator mask. Apply an electric sander to the fiberglass box. Smooth out every surface and flatten out every sharp edge.

9

Position the finished box into the area where it will fit. Trace out the cavities necessary to connect the carburetor to the intake manifold and where the fuel line will enter the box. Remove the box and drill the necessary holes with a power drill and bore bits. Sand out the edges.

10

Paint the box with a durable spray paint. Install the final product and connect your carburetor.