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Getting a good cosmetic surface finish with carbon is properly difficult.
The internal surface matters more, since I'd hope he'll spend more time driving it than looking under the bonnet.
Emyr-
since I'd hope he'll spend more time driving it than looking under the bonnet.
What about the gram tho?
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The internal surface shouldn't really matter at all, since what you're aiming for is just a big volume of air, rather than a smooth surface for the air to flow over. The surface would only matter if the airbox was acting as a restrictor, so that you're trying to squeeze as much air through a confined space as possible. If you airbox is acting like a restrictor, you be doing it wrong. In any event, a little bit of turbulence is not necessarily a bad thing. Cylinder head ports flow better with a slightly rough surface than a polished one.
jambon
Brommers
Ah, so ITBs are back on the table? I've made a custom airbox from GRP, but it was a bit rough and ready:
The plastic bit bolted to the ITBS is the part of the standard Yamaha airbox, the rough looking black bits are the parts of the airbox I made myself. There's an ITG panel filter sandwiched between the two parts, and the hole on the front is connected via a flexi pipe to a NACA duct in the bonnet bulge. If you want something suitably pimptastic, I suspect the easiest way to do it will be a CAD file of the part, and the services of a pattern maker and a laminator. Getting a good cosmetic surface finish with carbon is properly difficult.