Building my own cold air intake

[alkemyst]

Well, I'm back. Get used to it. I wonder how they measured the ram air effect when they were standing still. Anyways, go back and read my post carefully, taking everything into consideration, including the physical aspects of it. In other words - resistance, is futile.

they have these things called like fans and shit.

 

[AMCRambler]

Finished the second half of layer two tonight. Once that sets up I'll sand it and put the final layer on. Once that sets more sanding, bondo to even it up, sand and block it smooth and put one more layer of resin on for the final finish. Almost there!

 

[AMCRambler]

Top layer of fiberglass is now finished. I'm debating whether I want to do another layer of resin on top to try and create a nice glassy finish or just leave it rough. As you can tell from my engine bay I'm not super concerned about under the hood looking all clean.

[img[http://pics.bbzzdd.com/users/amcrambler/FiberglassDone2.jpg[/img]

Checked the fitment and everything is good. Hood closes nice and I won't even have to take the insulation off. It makes for a nice cushion. I'll probably get some adhesive foam for the bottom to protect the radiator shroud and intake from rubbing each other.

Next step dissolve the foam, clean out the inside and cut the opening to size for the filter.

 

[AdamK47]

Form looks good. Could use some serious sanding.

 

[AMCRambler]

Foam is dissolved out now. It was cool when the acetone hit it, sizzled like a mother and turned into purple goo.

Probably going to sand and coat it with one more layer of resin to even it out before I call it done. Tomorrow I'm going to head to Home Depot and get some angle iron to hold the filter in place. Then cut the hole to size and get it all put together. Last step is to drill a hole for the heater hose fitting that the PCV line will connect to. I'm hoping I get it done and test it out tomorrow.

 

[TridenT]

Looks like you will easily gain 500-600 hp.

A conservative estimate to say the least!

 

[AMCRambler]

Yeah hoping to finally break the wheels loose with this bad boy! Might even catch some Honda Civics from a roll. Can't touch them from a dig....lol.

Almost done. One final mock up tonight with the filter bolted in and the MAF in place.

Just have to drill a hole for the hose flare for the pcv line and mount that. Re-route the MAF wiring and I can test drive it. I bet it'll get at least 100hp on the butt dyno.

 

[chucky2]

Is that the stock rubber piece linking the throttle body and your new intake together, or one you found and used?

Just wondering if it's not stock, any concern under good amounts of throttle of having it deform inwards.....

Chuck

 

[AdamK47]

Is that the stock rubber piece linking the throttle body and your new intake together, or one you found and used?

Just wondering if it's not stock, any concern under good amounts of throttle of having it deform inwards.....

Chuck

Not a stock part.

 

[AMCRambler]

I got the hose for the intake online at intakehoses.com. I've got a hump hose that I still need to cut to size that will go between the throttle body and the MAF. It has a hump in the middle which will allow it to flex as the engine moves. It was 10pm and my arm was tired from sawing the first hose so I just mocked it up with what I had to check fit.

The hose you see there was originally one straight piece I cut in half. I've also got two inserts for the MAF side of each since the intake and TB are both 4" and the MAF on either side is 3.75".

 

[SSSnail]

So, you're gonna toss some band clamps on there right?

This one time, at band camp, I saw a hose just like that clamped shut during WOT. We couldn't figure out why the car would cut power at WOT on the road, then someone had the bright idea of popping the hood. Sure enough, the thing was clamped shut when it went WOT... man, good times, good times.

Edit: now that you have the complete product, and seeing what it looks like, I don't think you'll get enough air.

 

[EightySix Four]

So, you're gonna toss some band clamps on there right?

This one time, at band camp, I saw a hose just like that clamped shut during WOT. We couldn't figure out why the car would cut power at WOT on the road, then someone had the bright idea of popping the hood. Sure enough, the thing was clamped shut when it went WOT... man, good times, good times.

Edit: now that you have the complete product, and seeing what it looks like, I don't think you'll get enough air.

Why wouldn't he? It will pick up quite a bit of airflow in that location and the intake hole is pretty large...

 

[Vette73]

Did not see this the when it came up. But if you or anyone else plan on building these a lot and need fiberglass stuff. Go to a boat supply shop. When I was a tech I worked near a bodyshop and saw fiberglass supplies with boats on the side of it. Was told boat shops buy and sell more fiberglass supplies so they sell them much cheaper than a body shop supply house that is set up for mostly steel cars, not fiberglass.

 

[SSSnail]

Why wouldn't he? It will pick up quite a bit of airflow in that location and the intake hole is pretty large...

If you really look at the design and the filter, the only air that's getting through is just by the thickness of the filter, minus the volume being blocked by the rubber surrounds (since it's resting against the enclosure. The rest of the surface area is moot, doesn't serve any other purpose.

If you're thinking he's getting any "ram air effect" from this, that's also wrong. The lips of the enclosure blocks any air that's coming through the slits between the hood and the bumper, the other area of the filter is blocked by the bumper.

 

[AMCRambler]

Pretty much done. I need some bigger band clamps. My four inchers are stretched to the limit and I can't snug them down as tight as I want. I didn't have one that would fit around the intake mouth but thats in there pretty snug all by itself.

Test drove it tonight and it worked good. Little more noise up in the front from the engine which is nice but it's not screaming loud. Car seems to have more balls in 2nd and third gear too. 2nd it was really trying to bust the tires loose. I had to feather the throttle to keep it grabbing. I took it four a 15 minute ride around the block and down the four lane in the 55 got it up to 70-75. Car got up to operating temp and then I headed back to the house and popped the hood. The engine compartment was pretty hot but I put my hand on the fiberglass and I'll be damned but that thing was cold. I'm sure with a longer ride it'll get some heat soak but as long as you're moving that thing is really sucking some air.

I'm not sure how I can prove it's working besides getting some engine management tools and checking the IAT readings on the old intake and on the new but Svede already did that with his on the gto forum. He's also done some 1/4mile passes at the strip with one and then the other and he's picked up on average 4mph in the 1/4. He's proven the design and that's good enough for me. Just gotta get some better clamps and secure those hoses real snug and it's good to go.

As far as the hoses collapsing, its just not possible. The MAF has long ends on it that basically take up most of the space between the intake and the throttle body. The hoses just couple the two together. There's less then a 1/2" between the MAF and the TB and intake where the hose is stretched across an opening. It's so snug I can barely get the intake in there and connect it up to the hose. Pic of the MAF on the stock airbox for reference: http://www.redgto.com/kb/Attachments/67ec828b-f68f-4888-a08e-365f.jpg
I cut the intake opening back so that it would fit almost right against the MAF with the MAF right against the TB.

 

[EightySix Four]

If you really look at the design and the filter, the only air that's getting through is just by the thickness of the filter, minus the volume being blocked by the rubber surrounds (since it's resting against the enclosure. The rest of the surface area is moot, doesn't serve any other purpose.

If you're thinking he's getting any "ram air effect" from this, that's also wrong. The lips of the enclosure blocks any air that's coming through the slits between the hood and the bumper, the other area of the filter is blocked by the bumper.

I'm not, it just looks like a less restrictive setup than the airbox which also exists in those pictures. I'm willing to bet it's good for a few HP and lb.ft

 

[exdeath]

Curious to see how noisy your MAF output looks that close to the throttle body.

 

[AMCRambler]

I'm not, it just looks like a less restrictive setup than the airbox which also exists in those pictures. I'm willing to bet it's good for a few HP and lb.ft

I completely removed the old air box as well. Without it the engine compartment looks bare on that side, lol.

 

[AMCRambler]

Curious to see how noisy your MAF output looks that close to the throttle body.

Well, the air has a straight shot through the MAF but there's probably some turbulence due to it being that close to the TB. If I get the car tuned with the intake on there I'll see if they can give me some logging on it. No plans for that at the moment but I might look into it. They'd prolly laugh their asses off at my home made project at the dyno shop.

 

[joshuachavers]

Well, the air has a straight shot through the MAF but there's probably some turbulence due to it being that close to the TB. If I get the car tuned with the intake on there I'll see if they can give me some logging on it. No plans for that at the moment but I might look into it. They'd prolly laugh their asses off at my home made project at the dyno shop.

soooo...How well has this intake worked for you? I am currently in the process of molding mine out of the Styrofoam now and was wondering should I proceed with this project or is it a waste of time?