Baron's makes a great quality product in their Big Air Kit (BAK). However, unless you have the fingers of a triple jointed 12 year old female piano player, servicing the BAK is not a simple endeavor.
The problem starts with the fact that the outer cover is retained by some 1/4" fine thread (28 tpi) by an 1 13/16 in. bolts that thread in from the backside of the backing cover. The bolts are surrounded by the Air Temp Sensor, and hoses. This further complicated by the air filter having no retaining grooves etc to hold it in place. So you have to hold the outer cover, and the filter while blindly reaching in to thread the bolts into the outer cover. (See BAK Stock image)
My first install took about 20 minutes and some angry words to make it through. So being a lazy slob I thought about a cheap and simple workaround.
Parts Needed:
2 - 2 inch long exhaust studs (1/4 by 28 tpi on one end and 1/4 by 20 tpi) or 28 tpi on both ends I could not find one (Ace Hardware # 63522)
2 - 1/4 by 20 tpi nylon locking nuts (aircraft nuts)
1 - tube of blue threadlock (I picked blue because it it not as permanent)
Steps:
1) Remove the BAK outer cover by removing the two retaining bolts highlighted in the first image (BAK stock image)
2) Remove the retaining bolts and spacers from the BAK backing plate (you will reuse the spacers)
3) Clean off the inside of the BAK outer cover and dry the threads of the lower two retaining bolt holes.
4) Install a drop of threadlock on each of the 2" studs on the fine threaded end of the stud and thread the studs into the outer cover lower two mounting holes (see image install fine threaded studs w threadlock)
5) I took a small set of vise grips and gave the stud a 1/8 turn to snug it up, the outer cover only has a small depth to it so do not over exert yourself and damage that very nice chrome.
6) I then added a little teflon tape to each stud on the unthreaded section of the studs to hold the spacers in place (about 3-4 rounds of tape will add just a little drag and keep the spacer in place). (see image adding teflon tape)
7) Now put the spacers onto the studs and over the teflon (these are important to keep you from crushing the filter). (see image spacers in place).
8) Now its time to remount the cover and filter.
a) place the filter into the grooves on the backing plate.
b) use the outer cover to trap the filter in place while lining up the studs with the backing plate mounting holes. (make sure the filter stays in the grooves.
c) while using your left hand to hold pressure on the cover, take your right hand and start the lower retaining nut (use the 1/4 in by 20 aircraft nuts) and tighten with a wrench until in is barely snug.
d) recheck the filter and the grooves, loosen and start over if it is out of place.
e) now start the much harder upper nut (made easier since we ditched the goofy bolt setup) tighten until just snug.
f) now finish tightening (just past snug) the lower retaining nut.
9) Recheck the filter and alignment to the grooves.
10) Your done! Now you can the filter swap out to clean it in under 5 minutes with less chance of cross threading that nice outer cover.
In retrospect this costs about $7 to do with what I cited. You could have used threaded rod (fine thread) and made your own studs. I liked the higher tensile strength of the studs (actually exhaust studs). I would own a Gearwrench or similar 7/16 in ratcheting combo wrench to make this easy.
The problem starts with the fact that the outer cover is retained by some 1/4" fine thread (28 tpi) by an 1 13/16 in. bolts that thread in from the backside of the backing cover. The bolts are surrounded by the Air Temp Sensor, and hoses. This further complicated by the air filter having no retaining grooves etc to hold it in place. So you have to hold the outer cover, and the filter while blindly reaching in to thread the bolts into the outer cover. (See BAK Stock image)
My first install took about 20 minutes and some angry words to make it through. So being a lazy slob I thought about a cheap and simple workaround.
Parts Needed:
2 - 2 inch long exhaust studs (1/4 by 28 tpi on one end and 1/4 by 20 tpi) or 28 tpi on both ends I could not find one (Ace Hardware # 63522)
2 - 1/4 by 20 tpi nylon locking nuts (aircraft nuts)
1 - tube of blue threadlock (I picked blue because it it not as permanent)
Steps:
1) Remove the BAK outer cover by removing the two retaining bolts highlighted in the first image (BAK stock image)
2) Remove the retaining bolts and spacers from the BAK backing plate (you will reuse the spacers)
3) Clean off the inside of the BAK outer cover and dry the threads of the lower two retaining bolt holes.
4) Install a drop of threadlock on each of the 2" studs on the fine threaded end of the stud and thread the studs into the outer cover lower two mounting holes (see image install fine threaded studs w threadlock)
5) I took a small set of vise grips and gave the stud a 1/8 turn to snug it up, the outer cover only has a small depth to it so do not over exert yourself and damage that very nice chrome.
6) I then added a little teflon tape to each stud on the unthreaded section of the studs to hold the spacers in place (about 3-4 rounds of tape will add just a little drag and keep the spacer in place). (see image adding teflon tape)
7) Now put the spacers onto the studs and over the teflon (these are important to keep you from crushing the filter). (see image spacers in place).
8) Now its time to remount the cover and filter.
a) place the filter into the grooves on the backing plate.
b) use the outer cover to trap the filter in place while lining up the studs with the backing plate mounting holes. (make sure the filter stays in the grooves.
c) while using your left hand to hold pressure on the cover, take your right hand and start the lower retaining nut (use the 1/4 in by 20 aircraft nuts) and tighten with a wrench until in is barely snug.
d) recheck the filter and the grooves, loosen and start over if it is out of place.
e) now start the much harder upper nut (made easier since we ditched the goofy bolt setup) tighten until just snug.
f) now finish tightening (just past snug) the lower retaining nut.
9) Recheck the filter and alignment to the grooves.
10) Your done! Now you can the filter swap out to clean it in under 5 minutes with less chance of cross threading that nice outer cover.
In retrospect this costs about $7 to do with what I cited. You could have used threaded rod (fine thread) and made your own studs. I liked the higher tensile strength of the studs (actually exhaust studs). I would own a Gearwrench or similar 7/16 in ratcheting combo wrench to make this easy.