To start, the high-grade polyester foam used to manufacture No-Toil air filters is made through a chemical reaction that occurs when you introduce two different chemicals to oxygen. The reaction occurs almost immediately and from it comes the rising foam material. When making our flame-resistant filters, we also include a flame-retardant additive into the mixing process before the foam is produced. This saves us from adding it later and makes sure your air filter isn’t prone to catching fire in extreme heat or from sparks. 

After resting for some time, the foam is placed in a large machine where it is cut to a specific size and shape and then glued together from beginning to end. Once the layers of foam are shaped, they go through the flame lamination process, which is meant to bond the two layers together. During flame lamination, each layer rolls over a small flame allowing the two sheets to adhere and bond together, offering you durability and more consistent airflow.

Once the bonding process is complete, we have our pieces of foam die-cut using an assortment of molds for different motorcycle models and manufacturers. These molds are what helps us ensure your filters meet OEM specifications, so they fit right every time. Once the pieces of the filter are cut, they are sent over to the final step in the process, the gluing area, where we apply a secret type of high-strength aircraft-grade glue to specific areas so your filter stays put together in one piece. 

With all that said, the process of making air filters isn’t as easy as one might have thought before. There’s a lot more that goes into the process and a lot of different factors most don’t take into consideration. For example, some of the ingredients we use to construct No-Toil filters are currently unavailable globally, which is why all standard, extreme condition and pre-oiled air filters have been out of stock on our website since June 2020.

As we continue to work towards restocking our online store, please remember all No-Toil filters are reusable and, when treated with our proprietary No-Toil Air Filter Cleaner and Classic or Evolution Air Filter Oil, can transform into a new one within minutes.

We hear you clearly and want you all to know our team is doing absolutely everything possible to get air filters available for purchase on the site as soon as possible.

Until then, we encourage you to visit the website of one of our trusted retail partners to pick up your No-Toil products today! 

This is the latest update as of March 2021. Please be sure to subscribe to the No-Toil newsletter to be the first to know once we have all our filters back in stock and ready to ship to you!