My PFS intake (the big box) rubs/bangs on my PFS stockmount I/C and makes all kinds of noise. I'm slowly trying to eliminate noises and this is next on my list. What would be a good material to put inbetween the plastic and metal of the I/C to prevent the noise? Just a 1/4" thick piece of rubber or something? Anyone else have the PFS intake and stockmount and have this prob?

 

Just make sure it's something that will stay in place either with glue or by being a really tight because it will fall out if not and maybe block one of the radiator fans

 

Depending on how often you pull your air box out I would probably use some thick doublesided tape. You can get it at the hardware store for cheap. It works well for holding things in place and for a buffer. The only problem is sometimes it is difficult to remove.

 

That's what I was thinking ... but it will be touching the side of the I/C and that thing gets pretty damn hot. Wouldn't it just melt the tape?

 

what about some of that mole skin things people put on their feet? It's padded on one side, and has adhesive on the other. Have the padded side touching the IC.

Tim

 

Hahaha, good thinking. That would probably work, I just don't know for how long. That I/C gets pretty damn hot, which is why I'm thinking that some type of thin rubber piece might be better. Hmm ok well thanks for the ideas guys ...

 

I don't know how it would make much noise. My intake rubs slightly on the side of the IC but with everything properly installed, there really isn't much movement. Of course, the IC also rubs against the battery hold-down post and the front corner of the intake just rubs the hood too. So there you go......

BTW, I would go putting a layer of rubber between the components. Then you get squeaks from hell..... Try putting something softer or slicker than rubber. Of course, you could just make sure everything is installed properly. You might have to tweak the rear of the box more towards the passenger side of the car.

 

Thanks for the reply. I don't know - I just bought the car last week. But the PFS airbox is about 1/4" away from the I/C, and bumps against it quite a bit. The plastic of the box banging on the metal of the I/C creates quite a bit of noise. There doesn't seem to be much holding the PFS box in place other than the hoses that are attached to it. Yes? Also, how the heck do you remove the box ... it seems like you can't even remove it without first removing the entire intercooler, because its slanted on that side and bumps into the IC. LOL

 

You hit it right on the head. You have to remove the IC to remove the intake.... I think PFS may have tried to emulate Mazda functionality a little TOO closely....

My point is neither the IC or intake should be moving around AT ALL in the car. Is the intake box resting on the chassis rail? Is the IC firmly resting on the crossmember and bolted to the duct?

What kind of noise exactly are you hearing?

 

The I/C is rock solid, doesn't move at all. The intake box is resting on the frame but aside from the hoses there doesn't seem to be anything keeping it from moving side to side, and so at times it bangs against the I/C. Maybe I'm just **** but I'm trying to get rid of all the random rattles, etc.

 

There should be no movement at all. If it's moving around a clamp &/or a hose is off. It is held in place by the clamps that attach to the intake pipes and the coupling running from the airbox to the cold air duct. Do you have that coupling? Do you have the duct? The airbox can't touch the intercooler if the duct is properly installed.

To get the air box out, you have to pull out the battery and battery tray, remove the coupling running from the box to the duct & pull the intercooler. Then just loosen the clamps holding the air box to the intake pipes running back to the turbos, & out it comes. Its really about a 10 minute job.

Then take out the screws in the box and NOW, you can clean your air filters. PIA+ but the thing works well.

When you put it back together right, you get no lateral movement of the air box at all.

 

The hardest part of removing the PFS IC is removing the two duct bolts (actually reinstalling them - removing them is'nt that hard). I installed the small battery (tray by Jeff H.) and that elliminated the battery hold down rubbing on the IC. The air filter box does rub on things. Mine has almost rubbed through. I put electrical tape on it where it rubs so it will do no further damage. I suggest door sealing foam from Home Depot etc. It has sticky tape on one edge. You can get it in different thickness and width.

I also installed an "air director flap" inside the IC duct, to try to reduce the intake pulling air from the engine compartement through the IC. Not sure yet if it does the job. I plan to install an array of 12 V computer fans on the engine side of the IC to ensure air is always flowing towards the engine.