Okay, as ya'll know I am currently in the process of modding my Savage with the help of all of ya'lls advice.

Currently I have a Jardine slip-on muffler installed. Have removed plug over air mix screw, and have done the half spacer mod.

I have ordered:

K&N Drop in air filter
Front brake pads
Rear brake shoes
#55 Pilot jet

I have a 152.5 Main on hand

Now what else do ya'll suggest. I keep seeing mention of swiss cheesing the air box. In what area of the box to you propose I should drill out?

Is there anything else that can and should be done with very little monetary expense involved?

After I get engine running the way I want, I will be starting on looks.

I agree. I drilled the door to my airbox and my bike ran like crap so I bought a new one(eBay) to replace it. I then proceeded to remove the snorkel and that proved to be a better alternative. With the K&N I would suggest starting with the snorkel removal and then work it from there.

If you are going to put the cone filter on, no need to cheese the door. I cheesed mine to see how it would breathe. Seems to be just fine. If that didnt work, I was going to the cone.

I think ( hope) they are referring to the rubber piece that goes just under the seat. It is what the air goes thru first as it begins it's journey into the airbox. It makes the inlet tighter than necessary. Pop the seat off & look straight down at the path the air takes entering the airbox, you'll see it.

i opted to swiss cheese the air box door, because the snorkel area got a little cluttered, when i moved the regulator there, to accomodate my version of the sportster seat mod. how ever you opt to do it, you need to add air flow to the intake.