I was going to detail and post the whole process of my mod but once I got into it I realized it kept changing as I went along.  So here is a description and pics of what I did.

- Removed front of airbox and cut out chamber to house a fabbed battery shelf.
- Made battery shelf out of 18ga with front lip to bolt onto existing battery mount holes.
- Discovered that stock battery was a little large so I bought a 12A-A battery from Farm and Fleet. Fit perfect.
- Made front cover with lip to fit into the 1/16"opening on the airbox lip where I had removed the front.
- Made provisions to mount the tool case on the front of the new front cover. The tool case is now mounted sideways.
- Made metal plate to fit in the right side cover to locate the rectifier.
- Removed rectifier from rear fender and rerouted wiring to locate it in the side cover.
- Made a wire to ground rectifier plate to right side airbox mount bolt.
- Bought chrome M6 bolts, washers and rubber washers from hardware store to mount fabbed shelf and front cover to the old battery mount holes.
- Put cone filter on and fired it up. Works and looks great.
https://www.bikepics.com/pictures/2136759/



I spent a silly lot of time doing this and figuring out how to do it but I am real happy with how it came out. I originally thought I was going to fab the whole thing then realized that maybe I could maintain the old airbox and side panels, and modify the airbox to hold the battery.

This got started by wanting to put a cone filter on. Then I saw what they had done with the Ryca. So I jumped in to get the battery between the frame.

I am very very happy with this. Now on to other things. Drag bars. Longer shocks. I'm thinking about the Dunstall 17" reverse cone muffler. Chopping up the fender. Getting rid of fender chrome and so on.

Please feel free to contact me if anyone has any questions. Happy riding.

Okay, here we go. Hope this isn't all too boring. At least for humor you can see an old Schlitz box in one of the pictures. Made in Milwaukee.

Tools
- jig saw with metal blades
- angle grinder
- various metal files
- various clamps
- small combination square
- scribe
- bench vise
- small brake from Harbor Freight. Pretty much a piece of crap but I managed to get bends done with it by clamping down the top bar.
- other obvious small tools
- razor knife, hacksaw, drill and bits (not pictured)
- friends MIG welder

Materials
- 18ga sheet metal from Menards
- 22ga sheet metal from Menards, only used on sides of battery box
- small piece of 16awg wire
- 16awg disconnect crimp connectors
- 16awg crimp ring connectors
- emery cloth
- body putty and plastic applicator

Process
- First I cut up the airbox. You can pry the front off. Do not cut it off or you will loose the groove that the front cover will fit in. Use a razor knife and hacksaw to cut out the back housing that fits between the frame but leave the bottom and the captured screw tab on the bottom. This allows you to still mount the box with all original mounting points. The opening will be 3 1/2" wide by around 7" tall.
- I mocked up a wood shelf to make sure everything would fit together and mount properly.
- The dimensions for the parts are in my drawings but I can not swear that they exactly accurate. Maybe between the pictures and drawings you can tell what was bent and what was welded.
- It was a long process of cutting up the parts, making bends where necessary, making sure it all would go together properly, and welding it up. I have cut up pieces of metal left over that I did not like the way it fit or was not happy with.
- Welds: I made all welds on the front cover from the back side and all welds on the battery box were made on the outside
- Bends: I made some bends on the brake, a couple in the bench vise, and the longer rolling bends on the side panel I basically formed around a pipe.
- Tool case holder: I did not cut the edges off the tool case holder. The top lip lands on top of the front box and I cut a slit in the front box for the bottom lip to fit in. I had to make and weld a couple of plates to the side of the front cover that would accept the tabs on from the chrome tool box cover. The front plate of the new cover also was cut so that the key latch flange was a part of it.
- I used 10-31 screws and welded 10-32 square nuts for mounting the tollbox plate and the rectifier.
- I used silicone caulk to hold the rectifier plate in the side cover.



There is a picture of an extra front shelf plate. I made 2 in case I needed the thickness. I didn't need it.
The notch is for the cables to pass through. It is in the plate and the bottom of the front cover.

I think that's it.

I don't think it needs any grounding.
Plenty installs where they've said to have 'dropped' it in the airbox.
So I assume no connection at all.
I've have mine loosely positioned behind the seat for awhile now w/no issue.  But at least open to the air.  And haven't noticed anything hot back there.  

Stories go it will get hot if you have a charging problem though.  Not sure if it is caused by corroded connections.  But if your boiling batteries, then your rectifier will be hot.

Make a hole that when the rectifier is installed, it covers most of the hole for the wires.

Have you considered making these to order?  Could be a great product considering the amount of people that want to ditch the air box and go to a cone.  It just look too funky with no air box and the battery staying put. The finished product looks almost stock.  

Best mod I've seen for this though.