Safety-Info

Geometry

L / XL / XXL

The new AIRbox L based on the old XL version and is designed for all 10″ models. The AIRbox L has a very narrow top section to fit on all common 10″ Vespa models. The AIRbox L also fits well even with moderate lowering using shorter shocks.

The new AIRbox XL2 is a redesigned AIRbox XL. She is designed for the PX and all older 10″ chassis. The top section is wider, similarly to the XXL. This provides space for the new idle adjustment sleeve. This new sleeve allows adjustment from the outside.

The new AIRbox XXL fully utilizes the available space in the Vespa PX. However, the correct function of the shock absorbers and silent blocks is crucial here. The new designed sleeve allows adjustment from the outside.

Old / Lusso

The AIRbox ist made for the old carburetor trays without oil pump. The AIRbox Lusso is specifically designed for the carburetor tray with the oil pump.

With an appropriate shock absorber length, the AIRbox XXL can also be used on older models (see sketch).

Before installation, it is essential to check the correct condition and position of the shock absorbers and silent blocks.

The shock absorber length from the upper mounting point in the frame to the center of the eyelet should be 41.5 cm (original), but must be at least 40 cm.

The distance between the carburetor box and the tab of the side panel should ideally be 13.5 cm, but must be at least 12.5 cm.

If the clearance is less than 12.5 cm, the AIRbox may contact the chassis under full load and depending on riding style (compression travel), which can lead to damage to the paint and the AIRbox.

Strengths

All components are made from thermoplastics due to manufacturing requirements. The tensile, compressive, and impact strengths of these materials are significantly lower than those of aluminum and steel. For example:

• Tensile Strength: ASA: 40-50MPa, 60xx Alu: 300MPa
• Impact Strength (Notch Impact): ASA: 20-25kJ/m², 60xx Alu: 100-150kJ/m²

Fixing the AIRbox by „feel“ or with torque alone does not work based on experience. The risk of breakage is too high due to the significantly lower material strengths.
The M5 mounting screws come with appropriate nitrile rubber washers. The screws should be tightened by hand until finger-tight, then preloaded according to the diagram with at least 90° to amaximum of 180°. The washers also serve to self-lock the screws.

The fixing screws of the Venturi Race are secured by the top part to prevent loosening or falling out. In the Venturi Sport, the screws are inherently secured by the design to prevent falling out.The tightening of the Venturis must be done „by feel“ with a maximum torque of 0.5 Nm.

The screw connections must be checked regularly: first after 200 km, then every 1000 km.

Filaments

All components offered are produced using the FDM 3D printing process. Only ASA and PETG branded filaments are used, which, according to their manufacturer’s specifications, meet the requirements for each application.The key properties of ASA (Acrylonitrile Styrene Acrylate) and PETG (Polyethylene TerephthalateGlycol) are:

• Weather-resistant
• UV-stable
• High impact and shock resistance
• Scratch-resistant
• Heat-resistant
• Resistant to many oils, gasoline, and fats
• Abrasion-resistant
• Good chemical and high-temperature resistance

Manufacturers often mix fillers and additives of their own formulation to achieve specific advantages and/or minimize issues during printing (such as warping, stringing, etc.). However,these additives may negatively impact key properties for us, such as gasoline and oil resistance,temperature stability, notch impact toughness, and elasticity.
In FDM 3D printing, only thermoplastics are used. Plastic components do not reach the samechemical, mechanical, and thermal resistance and long-term properties as metals or compositematerials.

Therefore, we must emphasize proper handling during assembly and operation:

• Despite good chemical and high-temperature resistance, the maximum temperatureof 80°C should not be exceeded
• The components are resistant to many oils, gasoline, and fats, but they should not be immersed in solvents (gasoline, acetone, nitro thinner, etc.) as they will swell and lose strength. Various 2T oils (synthetic/mineral) can also affect the strength of 3D-printed parts
• The notch impact strength of ASA and PETG is around 4 J,while steel and SI aluminum are approximately 28 J and 20 J, respectively. Therefore, proper handling is essential. The tolerances of all components are designed so that, except for the mainframe, everything can be assembled without tools by simply snapping or twisting (bayonet connectors)
• Assembly of the components must be done with the included screws, rubber washers, bolts, and rubber bands, following the assembly instructions
• All parts are checked after printing, residue is removed, and connections are tested. If any burrs are found at the connection points, they should be removed with fine sandpaper(280+) or a fine round file
• The AIRbox XL and AIRbox XXL should only be used with a properly functioning shock absorber and correctly positioned silent rubber. The available space in the chassis, especially with the AIRbox XXL, has been maximized. If the shock absorber is defective or the shock length is shortened (including the top mount), the AIRbox may contact the chassis when it compresses and break. Parts may enter the engine compartment and damage the engine

For the reasons mentioned above and based on our experience, we must assume that high-load 3D-printed parts have a limited lifespan. Specifically, the Venturi jet is highly stressed due to constant exposure to gasoline, mineral oils, temperature, and vibrations. Therefore, it is likely that replacement will be required every few years.

Adhesive

To achieve optimal tuning results, the geometry of the AIRbox XL and XXL has been optimized compared to standard boxes. Due to the slanted cover, divisibility, and the additional intakeopening, the 3D printing process became more complex. Therefore, the cover and the intake opening parts of the AIRbox are printed separately and later bonded together.

The best results were achieved with cyanoacrylate adhesive. This adhesive penetrates deeply and „welds“ the two parts together irreversibly. Cyanoacrylate adhesive is also resistant to gasoline. To further increase the bond’s durability and provide better protection against vibrations, the parts are additionally sealed with a special automotive adhesive.

If any bonding comes loose during operation, it can be safely repaired with cyanoacrylate adhesive.

STVO (Road Traffic Licensing Regulations)

!!All componentsare without TÜV certification and therefore not approved for public road use. Tuning parts for racing and testing purposes, use at your own risk!!