zullo

I think I have something I can contribute to the forum for a change. Hopefully some of you will find this idea useful for fabricating a relatively inexpensive intake.

Basically, a reasonable intake can be fabricated from a couple K&N filters and some hard pipes. The problem is what to do with the other hoses that utilize the air box, primarily for muffling. If left to vent openly, the result is an annoying cacophany of whooshing and mooing...

So, what to do with the auxiliary hoses? I took my idea from the Apexi intakes and fabricated a "manifold" for attaching the hoses.

Here are the parts:

6061 aluminum 2 1/2" tubing, 2 copper 3/4" "street" elbows, high-temp epoxy putty, and high-temp paint.

I looked for some aluminum elbows but couldn't find em...

First, I drilled out a couple of 1/2" holes in the aluminum tube, then filed and sanded the parts to fit and ready them for epoxy and paint:


Here are some pics of the parts assembled, epoxied, and cleaned up:



One thing to note is that I layed a coat of epoxy to harden between the aluminum and copper - else some metallurgical reaction would inevitably take place and eventually corrode the joint...

A couple coats of high-temp paint later...

Ain't that purty?

And finally, some pictures of it in place in the car.




I like how it happens to also stagger the filters so they fit cleanly along the side of the engine bay.

Including hard pipes, k&n filters, and parts, this intake totaled about $100 - $110. Not bad.

Oh, the "moo" hose I handled separately - maybe worth a write-up once I come up with the most effective muffler for it.

Damian's heat shield is done and works great - just didn't make it in in time for the pictures!

Hope this gives someone some ideas!

cloud9

iTrader: (4)

I am impressed

reza

Lookin good.

It looks like the top filter will hit the smog pump pulley No?

scotty305

iTrader: (2)

Wow. Paint makes that thing look downright not-ugly. Does it do a good job of quieting down all the weird noises also?

-s-

zullo

Good call reza. I built a bracket to hold it off a half an inch or so...

That was, however, after the hose clamp rubbed on the pulley (just barely), but enough to melt the flange on the K&N.

K&N were more than willing to replace the filter - overnighted me a replacement! K&N rock!

gnx7

iTrader: (10)

I assume you shot the paint with an air compressed gun? That project turned out very nice indeed.

-GNX7

rzograbian

nice, btw, does that little breather fitler work to stop the cow noise coming from the air pump? the one that i have has a very small opening for the connecting part!


thanks... btw, i would be intrested in doing this but im going single!

yetisoldier

I can't see any of the pics

TainoIndian

iTrader: (4)

did you replace the intake accordion hoses or did you replace with metal ones cant tell from the pic?

Raziel

iTrader: (1)

Looks good. Nice work.

WaLieN

I must say, that is a very good job.

mrb63083

iTrader: (4)

Very good job. I'd try and make me one if i didn't already buy my Greddy intake

zullo

Thanks guys. I'm happy it didn't turn out too ghetto. And like I said I am real happy with the way it ends up staggering the filters. They otherwise had to be all cockeyed to coexist together with the hood closed.

qnx7 - yes, I sprayed the paint

rzograbian - the air pump filter has no effect on the mooing as far as I can tell. You have to muffle that on the return line that was previously muffled at the air box (top right corner). I've been trying various means to muffle that with limited success.

Taino - replaced accordion hoses with aluminum hard pipes. This piece extends the primary turbo intake pipe a few inches.

Saner

iTrader: (1)

Great idea/write-up, zullo. I just went the K&N route and was wondering what I was going to do with those hoses.. Perfect timing! Thanks!

dis1

GREAT job on creating something custom! So few people try this type of a thing unless you count cutting holes in the bottom of the stock air box. I too created a custom intake, although a bit more was involved. I spent about 175 creating mine but the time involved was a heck of a lot. Here is a picture, more of which are on my site. http://www.silverbulletrx7.com/Intake/Intake2.jpg Notice I plumbed the air pump in to the second turbo's intake pipe. Yours is open, which may not be good. I have heard that if the air pump sucks in hot air it will be damaged over time... or quickly.

Again great job. I get so tired of seeing posts about this bolt on or that and post about "here are pictures of my car and guess what, it looks just like yours except that I just washed it." This is the type of thing I like to see

zullo

Thanks dis - I have Damian's heat shield in now with the air pump filter plumbed to it - hopefully that will keep its temp down a bit

adam c

iTrader: (2)

Nice job. Looks very professional.

turbojeff

iTrader: (30)

Looks great! Thanks for the pics.

rynberg

Nice work! Looks like there's plenty of room there for a big SMIC or v-mount....

jpandes

Nice work! Are you going to make a heat shield too? I'd like to see how that turns out, too.

How do your BOV's sound?

TainoIndian

iTrader: (4)

any other homemade things you have made for your car to share with us!

DrunkenBowler

Not too bad.

Enconsiderate

great contribution!!!! looks very good.

widebody2

dis that thing is serious...looks like a whole heck of a lot of work went into that

dis1

Thanks widebody2, All I can say is that it gave me a new appreciation for both people like zullo that attempt something custom and the small companies like M2 that develop something for the masses. Next up is a custom exhaust and battery tray.
dis1