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?

Here is the modified fog light & duct setup to supply ram air.
top
http://208.62.166.66/guest/pics/intake/fog13.jpg
left
http://208.62.166.66/guest/pics/intake/fog14.jpg
front
http://208.62.166.66/guest/pics/intake/fog15.jpg
right
http://208.62.166.66/guest/pics/intake/fog16.jpg
back
http://208.62.166.66/guest/pics/intake/fog18.jpg

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?

Looks good:D

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!

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:

thats bad ass dood...

now this should get Archived, nice setup man ;)



-Shawn

Thanks for the compliments!:)

This setup doesn't use the brake ducting at all. The tube for the cold air actually falls right beside the ducting - which remains in the stock location untouched. (You can see it in the second pic.)

I supose that the headlight washer could have been an option - or maybe standard on Canadian GXL's. If you don't have it, then you still have the space for it! You could just relocate the Windshield washer resevoir to the other side. The hole for the headlight washer neck will still be there. Or even hunt around a scrap yard for the headlight resevoir.

As for the AFM, I did a bunch of research before I installed the setup, and I read and was told pretty much the same thing. If the AFM is mounted upside down - that's ok. It's only when you mount it sideways that it presents a problem. If it is on it's side, gravity will hamper the flapper's operation. Really, it functions upside down the same as right side up. So far it hasn't given me a problem!

I kinda like the red brace! for now anyway.....:D

Oic the brake ducting now...Nice work. Yea there is still a hole on the drivers side, and that was where I was planning on moving the washer resavoir..hope it isnt a giant PITA....

Thats phenominal. No ghetto foil-tape box for you. I'd love to weld one together, but I suck at welding steel, and I hear aluminum is much more difficult.

My GXL doesn't even have the sprayers.

I suppose the REAL question everyone's thinking about. Are you considering producing these? I'd buy one if you were :)

I would definately put it high up on my list of things to increase performance. But I still need to finish my list of things that are causing it not to run at all. :(

Yeah, welding aluminum is a bitch - thankfully I had professional help! Unfortuneately that help no longer is in a position to do much for me.:(

He gave me pretty much free reign in his machine shop, so I took some left over aluminum that he had, sheared it to size, and then it got all welded up. But now he doesn't work there anymore - so the answer is NO, I wont be selling them. Unless he gets the same kind of freedom at his new shop - but that'll be a while......

ViperKillerWannabe: Don't worry about the sprayers: Like I said before, if you don't have them - you still have the room for them and the hole for the filler neck. All you have to do is relocate the current setup to the other side of the car. Might be a PITA, but it eliminates the "ghetto look".;)

damn those are bling bling.

for people who can't weld... go buy a some JB weld... the box doesn't take any heat at all... so it will work good... just make sure u tape up the box somehow so that it allows the expoxy to take shape.

Nick any measurements of the box?

I was looking at my car today. I removed the washer resavoir and inner fender and everything, and I had an idea. Instead of having the PVC route air up into an air box, I think that I am actually just going to run the intake tube down through the hole and have the cone filter located inside the fender, by where your PVC intake thing is. Then I can do a little trimming and put my stock airbox back in (just for looks, it will be useless) so it looks nice and stock. What do you think about that?

Oh, and I am just going to relocate the washer bottle to the space where the hood latch is, between the rad and the bumper. THat way all the factory wiring can reach and I wont have to re-wire anything. Plus it still looks nice and clean there...

Heya Nick,

I'll be doing a similar setup as you. Except what I will do is instead of making an air box, I will put on one of those double-sided 3" filters (that have an in/out and a heat shield), and a flex hose to run from the tip of the filter, down into the duct behind the fog light... :D

Thanks for the idea!!!
-Ross

I have a question, would that work with a TID mod? Is it the same demensions?

yeah man thats a really hott look.... Props on a job well done! Im trying to figure how i am going to do something like that myself....

looks good, I thought about that. or cutting a hole in the hood somewhere, but there no sense in cutting up the outside of a 7.

damn i got mine ghetto rigged to et air from where the FTP was

looks good, nice fab on the cold air box man

Wow - back from the dead!

Thanks for the compliments guys!

Since then I have sealed it to the hood with some nice heat resistant foam rubber. (Straight from the aviation industry;))

It does produce some noticeable gains. I know that lots of fresh air is being forced in there as I have found leaves in the box after runs in the fall, and the inside of the PVC tube does get wet in the rain.:D

Great mod! If you can avoid rain coming into the airbox it 's going to be perfect :bigthumb:

man its nice to see another rx7 with that damn rust proofing. i cant wait to rip out my engine so i can powerwash all that crap off!

I don't actually get rain into the box. On the inside of the tube it is wet at the opening, and you can see water droplets being pushed along inside the tube by the wind. No water has made it into the box via the tube yet!

That stuff is such a pain in the ass! The previous owner of the car put it up for sale, and then lent the car to his dad the week. His dad got the car rustproofed because he thought it would be a selling feature.:rolleyes: The car has never been winter driven! Anyway, I don't mind it under the car - but waht a mess under the hood! When I put the new engine in I tried to get it all off, but no amount of powerwashing would remove it. I had to resort to a chemical solvant and a lot of scraping! It was a huge mess, and a lot of work but made a big difference.

Hey, it may be back from the dead, but it's good I saw this ;) Looks nice, and I'm usually pretty interested in custom cold air intake stuff because of reading of some before ^_^


That sucks about leaves getting in, I'll bet that's annoying.. Couldn't you put some kind of light filter over the opening to keep larger things out? Not very big at all, so it wouldn't restrict air flow much.. But good enough to keep some of the larger stuff out..

Washers for the headlights is a Canadian option only.

Nice way to do the cold air mod though.

James

It's not like a vaccuum!:D

Yes I have found leaves in the box, but no more than one or two at a time - nothing to warrant any type worry. If it ever became an issue I'd fab up some sort of screen, but until I start inhaling small woodland creatures or enough leaves to restrict air flow, I'll leave it as-is. ;)


Even if your FC wasn't equipped with the headlight washers, the space in which the resevoir would have been will still be there. That being said, you could sipmply relocate your windshield washer resevoir into that space, as the windshield resevoir is actually smaller than the headlight one. It might take some patience and creativity, but you could probably fab something up!

LOL small woodland creatures