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Got Cold Air? - I do! (Pics)

Well, this was a project that I've been half-heartedly working on while my car was in storage. Once it came out - I got to work. I wanted to have a true cold air system, so I came up with a way to draw cold air in from in front of the wheel - while still retaining my winshield washer system (more on that in a bit).

First thing was to remove the washer bottle, and cut a 3.5" hole in the metal under the stock air box. In that hole I put a 3" - 4" ID PVC reducer, and siliconed it in place:

1)
http://us.f1.yahoofs.com/users/491bd...ed.r.ATEkMTPUH

I then put a 45 degree bend on the other side, and extended the tube down beside the brake ducting. Here's a shot from the wheel well. You can see where the washer used to be (I'll explain in a bit).

2)
http://us.f1.yahoofs.com/users/491bd...ed.r.ArWxNuDa5

Now, to the enine bay. Using cardboard as a template, I contructed a box out of aluminum, and welded it all up. Once it was secured to the car I was able to properly cut out the AFM hole, as well as the inlet for the new cold air ducting. Once the AFM adapter was fitted with the K&N, it all lined up very nicely. Take a look:

3)
http://us.f1.yahoofs.com/users/491bd...ed.r.ALP7Exg.m

4)
http://us.f1.yahoofs.com/users/491bd...ed.r.A_us3C456

5)
http://us.f1.yahoofs.com/users/491bd...f09r.A3tNtAxLt

Here you can see down the tubing and actually see daylight at the end!

6)
http://us.f1.yahoofs.com/users/491bd...f09r.AIC5f.3j2

In this pic the filter isn't actually where it is supposed to be - it's sticking up a bit more than it should. I will be putting some foam rubber on the hood to completely seal the box.

7)
http://us.f1.yahoofs.com/users/491bd...f09r.AVaIVlMMy

Now, for the washer situation. I didn't want a ghetto install of the washer bottle, so I did some creative wiring. Because the car is a GXL, it came with headlight washers - and the resevoir was on the drivers side. Now, since I've used them a grand total of 3 times in 5 years, I decided that I could do without them. I rewired the pump (you can see the old connector in the second pic - the green wires are the new ones) so that the resevoir that used to be for the headlight washers now does the windshield. The only visual difference is that the washer tubes now go up the drivers side of the car instead of the passenger's side.

So in all, I have a new cold air intake, and all I had to give up was my seldom used headlight washers - I think I made the right choice.:) I hope you guys like it!

Dammit! why won't the pics work! I can email them to someone if they have a better host that I do!

I can host them.
Mail to Bill.Branning@co.clay.fl.us

I am considering that same setup.

damn!!! iw anted to see those pics
can you PM me wioth em or come up with a way for all of us to see em???

damn!!! i wanted to see those pics
try to get those up
im considering somethin similar

the fc has headlight washers?

SureShot, I sent you the pics - Thanks!

The setup that you have there is for an S5 - right? The S4 brake ducts are quite different.

Yes S5 -
I'm working on formatting your post.

A repost of Nick's write up ---

First thing was to remove the washer bottle, and cut a 3.5" hole in the metal under the stock air box. In that hole I put a 3" - 4" ID PVC reducer, and siliconed it in place:

1)http://208.62.166.66/guest/pics/intake/Intakehole.jpg

I then put a 45 degree bend on the other side, and extended the tube down beside the brake ducting. Here's a shot from the wheel well. You can see where the washer used to be (I'll explain in a bit).

2))http://208.62.166.66/guest/pics/intake/Intaketube.jpg

Now, to the enine bay. Using cardboard as a template, I contructed a box out of aluminum, and welded it all up. Once it was secured to the car I was able to properly cut out the AFM hole, as well as the inlet for the new cold air ducting. Once the AFM adapter was fitted with the K&N, it all lined up very nicely. Take a look:

3))http://208.62.166.66/guest/pics/inta...efromfront.jpg

4))http://208.62.166.66/guest/pics/intake/Intakefront.jpg

5))http://208.62.166.66/guest/pics/inta...kefromside.jpg

Here you can see down the tubing and actually see daylight at the end!

6))http://208.62.166.66/guest/pics/inta...akeholebox.jpg

In this pic the filter isn't actually where it is supposed to be - it's sticking up a bit more than it should. I will be putting some foam rubber on the hood to completely seal the box.

7))http://208.62.166.66/guest/pics/intake/Intakeside.jpg

Now, for the washer situation. I didn't want a ghetto install of the washer bottle, so I did some creative wiring. Because the car is a GXL, it came with headlight washers - and the resevoir was on the drivers side. Now, since I've used them a grand total of 3 times in 5 years, I decided that I could do without them. I rewired the pump (you can see the old connector in the second pic - the green wires are the new ones) so that the resevoir that used to be for the headlight washers now does the windshield. The only visual difference is that the washer tubes now go up the drivers side of the car instead of the passenger's side.

So in all, I have a new cold air intake, and all I had to give up was my seldom used headlight washers - I think I made the right choice. I hope you guys like it!

Very nice workmanship...

Yea - I know - not everyone has a 21" monitor.

I'll reduce them later.

Thanks a lot SureShot!

That looks great. I can't wait till I get my AFM adapter.

BTW Nick86 what brand are those rotors? how much? how well do they work over stock?

So nick...what did you use to cut the hole in the car? VERY VERY VERY nice setup you have going on there btw. :D

The rotors are KVR. Because I picked them up from their manufacturig site, they were $91 CAD ($63.44 USD - they sell them for $106 USD on their site) each.
www.kvrperformance.com

To be honest I haven't even tried them yet. My Master cylinder finally gave out as I was bleeding the brakes, so the car is still stationary unti I properly bleed the MC and the rest of the system!

Quote:

Originally posted by KiyoKix
So nick...what did you use to cut the hole in the car? VERY VERY VERY nice setup you have going on there btw. :D

I borrowed a 3.5" OD metal hole saw (Looks like the ones for cutting holes for door knobs) and just went at it. The metal there is actually really thin, so it took no time at all. I then put anti-corrosion coating on it, and sealed the whole thing with RTV silicone. (that's what all that orange crap is on the tube underneith!)

Thanks for the compliments!:)

What is the URL for the site? I am thinking about what brand to get for when I start the non "go-fast" mods. I like the brembos offered by the store but they are 120 each so I am not sure what the better deal would be.

What did you use to make the hole for the air duct?

Nice Box! :)

Dude, I would never give up my headlight washers... ;)

Oh yea...I screw the headlight washers :D. And that's one pretty ass rotor!

hey man--what are these headlight washers you speak of?? I have an S4 GXL as well, but I don't see anything like that on mine.

Go out to your car, and flip the lights up. Right in front of the lights there is a little spray nozzle (one on each light). These are controlled by a button on your headlight switch. Press it, and you get spray!

What usually happens is the switch blows, and is replaced with one out of a scrapped base model, so you don't get the switch at all.

The resevoir is on the drivers side under where the battery goes - it is much bigger than the window one (go figure), and the filler neck extends up by the battery.

Look at pic #7, you can see the filler by the battery.

Damn thats a job well done!

Anyone else notice that the hole on the drivers side is MUCH bigger than the hole on the passenger side? That'd be a perfect place to put a cold air intake, except it's on the wrong side of the engine bay.

Looks very nice, Im thinking of a setup very similar to that, only I dont really want to use the brake ducting. Also, that headlight washer thing must have been an option, because my car doesnt have one, nor did any other FC ive ever seen in person, and more than a few have been GXLs.. Also, It appears that your AFM is upside down...I hear thats a no-no, might want to turn it back over. I have the same strut bar as you, only I painted mine balck..:p: