PVC/Fiberglass insulated cold air intake
01-17-09, 08:28 PM
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PVC/Fiberglass insulated cold air intake
So I've been researching parts for my 83. not alot of bolt on parts that I'm finding but I found The links on diy cai. so I decided to one up it and make it look a little nicer. and possably keep more cold air.
So Here is what I'm doing so far. I bought a 1' of 2"id pvc pipe with a 45* and a 90* bend. some fiberglass resin and mat and 2" roll of fiberglass wrap/cloth. some heat sink tape.
First I made the bends and cut the pipe to length, i left 5 inches to be silped into the aircleaner tube to keep more cold air and easy installation.
Next I wraped the whole thing up -5" that goes into airleaner with heat sink tape the whole roll more on the 6" of strait pipe thats more exposed to the engine heat
Next I added the fiberglass mat and cloth and built it up to the joints of the pvc pipe for a smooth tube in other words for looks. note Still left the 5" of pipe to.... ect....
this step may take a few times to get to a nice and semetrical. (This is where I'm at)
Sand smooth,
Now i'm going to wrap the whole thing 5" included this time with one single spiral wrap done as smooth as possable.
And finally I'm going to mix in some blue tint into the resin and make it blue finished. I think I can even leave the cloth pattern and it should kind of look like blue carbon fiber. but I'm not sure yet. I'll post some pics when its done
next Install and take some pics of my pimpin new intake.
Every thing else I'm doing just like the a/c tubeing cai as far as relocating overflow tank and cutting a hole in the radiator support.
I'm **** about getting this to look nice so give me a day or so to finish.
So Here is what I'm doing so far. I bought a 1' of 2"id pvc pipe with a 45* and a 90* bend. some fiberglass resin and mat and 2" roll of fiberglass wrap/cloth. some heat sink tape.
First I made the bends and cut the pipe to length, i left 5 inches to be silped into the aircleaner tube to keep more cold air and easy installation.
Next I wraped the whole thing up -5" that goes into airleaner with heat sink tape the whole roll more on the 6" of strait pipe thats more exposed to the engine heat
Next I added the fiberglass mat and cloth and built it up to the joints of the pvc pipe for a smooth tube in other words for looks. note Still left the 5" of pipe to.... ect....
this step may take a few times to get to a nice and semetrical. (This is where I'm at)
Sand smooth,
Now i'm going to wrap the whole thing 5" included this time with one single spiral wrap done as smooth as possable.
And finally I'm going to mix in some blue tint into the resin and make it blue finished. I think I can even leave the cloth pattern and it should kind of look like blue carbon fiber. but I'm not sure yet. I'll post some pics when its done
next Install and take some pics of my pimpin new intake.
Every thing else I'm doing just like the a/c tubeing cai as far as relocating overflow tank and cutting a hole in the radiator support.
I'm **** about getting this to look nice so give me a day or so to finish.
Last edited by jinxed4dub; 01-17-09 at 08:37 PM. Reason: replaced to with new I'm high on fumes i think???
01-18-09, 12:41 AM
#2
Are you going to put a cone filter on it?
Reason I am asking, I had a modified Holley carb hat and some intercooler tubing that I used to make a CAI with a cone filter on the end. It worked great until the secondaries opened, and the car kicked and spat madly. I narrowed it down to what I believe the carb hat not being large enough in diameter to supply the air needed.
Just my 2 cents, and it sounds like you have an awesome setup.
Reason I am asking, I had a modified Holley carb hat and some intercooler tubing that I used to make a CAI with a cone filter on the end. It worked great until the secondaries opened, and the car kicked and spat madly. I narrowed it down to what I believe the carb hat not being large enough in diameter to supply the air needed.
Just my 2 cents, and it sounds like you have an awesome setup.
01-18-09, 01:54 AM
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Are you going to put a cone filter on it?
Reason I am asking, I had a modified Holley carb hat and some intercooler tubing that I used to make a CAI with a cone filter on the end. It worked great until the secondaries opened, and the car kicked and spat madly. I narrowed it down to what I believe the carb hat not being large enough in diameter to supply the air needed.
Just my 2 cents, and it sounds like you have an awesome setup.
Reason I am asking, I had a modified Holley carb hat and some intercooler tubing that I used to make a CAI with a cone filter on the end. It worked great until the secondaries opened, and the car kicked and spat madly. I narrowed it down to what I believe the carb hat not being large enough in diameter to supply the air needed.
Just my 2 cents, and it sounds like you have an awesome setup.
My next fiberglass project is going to turn th front sheet metal (in front of hood above bumper, into a functional airdam Kind of like original nightrider, and it should slam air into the carb by the time the secondarys open. I'm not sure if i want to make the whole part fiberglass, or just cut it and make the ducting. I'm not to that point I guess....
Update I've just about got the shape I'm looking for, I wish i had a power sander about now. I think for the duct I'm going to buy a 18" chunk of pvc and two of the conectors that have a j bend but go strait through.
cut the pvc long ways so its a half pipe and cut the two bends glue it together and fiberglass it up
01-28-09, 12:57 AM
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bump.
so I'm a bit of a slacker on updates, so here it is. I've got it done, I want to do a nother one soon now that i've got the hang of fiberglass a little better. It looks decent, much better than the a/c or dryer hose setups.
Now that my car has a few mods, cai, strait piped(no cats) 2" from header to cat back, and 2 1/8" cat back. Nice sound. and it actually breaks the tires loose without dropping the cluch 2 and 3rd if the road is smooth. I've also removed the A/C and all the components, and done a moderate weight reduction ie: no exaust heat sheld, no storage bins, no carpet, or panels in the back end.
soon to gut the front Interier, make some fiberglass door panels and a dash, mine is cracked and I can make a custom fiberglass one cheaper than those dash covers, and I can add to it, I'm also getting a small welder with gas soon. so I can build a custom roll cage out of cromalloy Steel. Then I can go Mad weight reduction. I'm also going to try and keep the roll cage fairly hidden by using small diamiter tubes, and butting it close as I can to the body, and making a thin fiberglass interior, plus a 35% tint to help I'm Going to keep the rest of my weight reduction a secret for now, But I'm going for feaher light body, that still has an interior. Kind of like lotus. but I'm going for a bit more hp than a modest 200. but probably about 300 to 350. on a 4.30/1 gear ratio lsd. I also plan on keeping my sterio, and adding to it a bit. but Only 8" subs on a small 250 watt amp, some small tweaters in the custom dash, and some 5 1/4 mids" for the front and 6.5"mids.
so I'm a bit of a slacker on updates, so here it is. I've got it done, I want to do a nother one soon now that i've got the hang of fiberglass a little better. It looks decent, much better than the a/c or dryer hose setups.
Now that my car has a few mods, cai, strait piped(no cats) 2" from header to cat back, and 2 1/8" cat back. Nice sound. and it actually breaks the tires loose without dropping the cluch 2 and 3rd if the road is smooth. I've also removed the A/C and all the components, and done a moderate weight reduction ie: no exaust heat sheld, no storage bins, no carpet, or panels in the back end.
soon to gut the front Interier, make some fiberglass door panels and a dash, mine is cracked and I can make a custom fiberglass one cheaper than those dash covers, and I can add to it, I'm also getting a small welder with gas soon. so I can build a custom roll cage out of cromalloy Steel. Then I can go Mad weight reduction. I'm also going to try and keep the roll cage fairly hidden by using small diamiter tubes, and butting it close as I can to the body, and making a thin fiberglass interior, plus a 35% tint to help I'm Going to keep the rest of my weight reduction a secret for now, But I'm going for feaher light body, that still has an interior. Kind of like lotus. but I'm going for a bit more hp than a modest 200. but probably about 300 to 350. on a 4.30/1 gear ratio lsd. I also plan on keeping my sterio, and adding to it a bit. but Only 8" subs on a small 250 watt amp, some small tweaters in the custom dash, and some 5 1/4 mids" for the front and 6.5"mids.
01-28-09, 02:37 AM
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btw I can't find my camera at the moment. I'll Post pics of cai asap. Also I can Keep this thread open and post all my diy projects for welding, fg, car audio. I'm going to spend a little on my engine. I kind of want to build it up N/A for a few reasons. BOV's are loud and attract unwanted attention by your local Police. If you live in a small town. they will stop u for a bs reason and check you out. I've never had to pop my hood, but. I've been questioned about what Mods I Have. and I replyed "Axil back exaust system (system being a key word here), Short shifter, and Cold air intake." and claim that its faster than a stang (it really was!!!). Now. Really This is what I was running. 2003 Mits Lancer; I had a cam welded and ground by a friend with a history of machine work. with a lath. I did the welds he did the balancing and duration lift stuff. I'm clueless on that part. Profesional tuned ecu thramers auto. 550 cc injectors hi flow fuel rail/pump/regulator, recessed valve pistons with molly rings to prevent interferance if timing belt broke. didn't work btw due to the lifted cam... lancers Not the evos are also a SOHC (not a DOHC) 16 valve 4 Banger stroker engine a 4G94 is a stroked out 4G93 found in a marage) ported and polished head and intake. throttle body spacer and bored over and moded throttle body. aftermarked radiator. kept engine cold I always had an insufficiant operating temp sensor poping up. like once every 3 or 4 months. it just ran cold. you could touch the engine after a 2 1/2 hour hard drive though the mountans and too the beach. it was warm but it wouldn't burn you. except the exaust. Aftermarket LSD cat back exaust, not axil back high flow cat. adj timing gears. coil overs. strut bars. This little N/A was very quick. till about 120 due to the speed chip. trammers wouldn't remove it. Bastards. It had some more little stuff proformace wires, and voltage stablizers. ect short shift. fiberglass front end fenders bumper hood. some hidden weight reduc... mods
(BTW I used to be a welder by trade. I've decided Just plain old metal fab is boring, expecially when you build pretty much the same thing over and over again but just a little diffent. I used to weld Race car chassies From chromealloy, from scrach. Real fiberglass body race cars. just like nascar but more for an pro am not nascar. I dont know the class. I just bult the frames. and engine mounts. parts for four links. and I got to rev the engiens from time to time. MMMM I always wanted to take a spin around the block. But I never got to put one in gear. We used a impact gun to crank the engine since they had no starters. Other benifits of that job were. since I drove the boss home he let me put race fuel in my car from time to time. I got a used once optima red top from a car that came back rolled and broken. and not one of my welds busted. but the cromeally was broken in a few spots. Driver got out with few bruses. They gave me the battery. I also was begging for one for about 2 months. But that was it for bennies, no med, dental, vacation, sick, retierment. nothing. Oh we got doughnuts once a week. What a benifit package. Optima was great though...
(BTW I used to be a welder by trade. I've decided Just plain old metal fab is boring, expecially when you build pretty much the same thing over and over again but just a little diffent. I used to weld Race car chassies From chromealloy, from scrach. Real fiberglass body race cars. just like nascar but more for an pro am not nascar. I dont know the class. I just bult the frames. and engine mounts. parts for four links. and I got to rev the engiens from time to time. MMMM I always wanted to take a spin around the block. But I never got to put one in gear. We used a impact gun to crank the engine since they had no starters. Other benifits of that job were. since I drove the boss home he let me put race fuel in my car from time to time. I got a used once optima red top from a car that came back rolled and broken. and not one of my welds busted. but the cromeally was broken in a few spots. Driver got out with few bruses. They gave me the battery. I also was begging for one for about 2 months. But that was it for bennies, no med, dental, vacation, sick, retierment. nothing. Oh we got doughnuts once a week. What a benifit package. Optima was great though...
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02-15-09, 03:07 AM
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first i leaned it out thinking i was running a little ritch, but i actually had to make it a little richer. I havent had any issues since. the inside of it stays cool even when its been on for awile. I like it but I plan on making a mold of it and losing the pvc pipe. its quite heavy with pvc. and using header wrap as an insulater. but i'm going to leave it for now. but eventually Ill get to it. I need to remove the rats nest and plug the holes
