Home Made Cold Air Intake Full Walk Through

[geea]

There are obviously many ways of doing this. This is how I did it and I'm very happy with the result.

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=175

Here is all the parts I used.

From Clark Rubber Oakleigh.

1/2 meter HOSE FLEXI-FLO 63mm BLACK = $12.48

From Bunnings Warehouse Noting Hill.

Pt. No. - 9311381152990 DWV-PVC FLOOR FLANGE D78 D07865 65mm = $2.51

Pt. No. - 4921965 GUTTER - ACCESSORY 90mm DIAMETER GUTTERPLUG $15.03

Pt. No. - 9310086628786 SCREWS-SELFTAP S/S PAN UNIPA UBS2010 6G X 10mm SPH UP18 $3.35

Pt. No. - 5829514 CLAMP-MULTI PURPOSE 06/03 70-90mm bulk mp4p $2.44 X2

Here are some photo's of the air box pre mod.

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=176

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=177

The airbox is easy to remove with an 8mm socket. You will probably need to undo factory snorkel too.

You then need to make a hole in the airbox. I did this very amatuerishly with a drill and hacksaw. Probably be alot easier with a proper drill attachment in the correct size.

I then attached the floor flange with a couple of self tappers.

Here is how it looked. (the gutterflange is on in these photo's where as you actually put it on latter).

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=178

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=179

You now need to feed the Flexi hose through below the head light. Its very tight and difficult. You will need to push till it sits flush on the spoiler at the bottom. (we will come back to this soon).

Take your gutterplug and cut out the middle part, so it looks like a sleeve.

Place both clamps loosely on Flexi pipe.

Slide gutterplug half on to Flexi pipe, leave approximatly 1cm room (to slide gutterplug on floorflange).

With gutterplug in place slide both clamps on to gutterplug and secure 2nd clamp so gutterplug is securely attached to Flexipipe.

With this done you can now attach the other end of the gutterplug to the FloorFlange in Airbox. Then secure firmly with the clamp. ( do this before securing airbox).

Now rescrew Airbox into place.

It should look like this.

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=180

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=181

Now place your hand in the hole infront of the intercooler and manouver the bottom of the flexi pipe so it is facing to wards the middle of the car.

I also bought a BMC filter ($190.00 from Autobarn Glen Waverly)

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=182

After replacing the airbox lid this is how it looks.

http://www.fordxr6turbo.com/photogallery/s...&aid=46&pid=183

Total cost (not including BMC airfilter) was $38.26 .

I believe this mod coupled with the original snorkle should give the "T" ample cold air.

Hope this helps a few of you guys.

[bdennis]

Geea,

Top job. Do you have pics of where you placed the other end of the pipe (near the intercooler??) I have been thinking of doing this myself. Did it feel any different under the right foot?

[geea]

Here are some photo's of the pipe near the intercooler.

Hope they answer your question if not let me know and ill get more shots. B)

Pipe near intercooler 1

Pipe near intercooler 2

Pipe near intercooler 3

Reguarding the feel afterwards. It might sound silly but I believe that it has more. It used to be that occassionally when backing off from full throttle there would be a little fluttering noise, now it seems to be more often and longer. (not sure exactly what the noise is -blow off valve possibly).

[rainy]

why cant u just attach the flexi pipe straight to the flange u put thru the air box?

[geea]

You could, but I was unable to. My pipe and flange were the same size and I was unable to find ones that were compatable.

[rainy]

Thanks,I was thinking that the pipe would go straight onto the first flange and wondered y -so there,u cleareed that up

[bdennis]

Geea,

Good stuff. Thanks for the pics. Before this post I had looked at where to plumb the pipe. Sh!t this is a lot of othre plumbing you need to get around to get the pipe down to the bottom of the front skirt. This will be the next mod I make... Thanks.

[dankman]

Definate mod for the Dank Mobeele when it finally arives.

Two weeks to go now

[harasn]

I have a couple of concerns about your mod!

1) The placement of the intake at the bottom of the the bumper! It will suck an awefull lot of water up into the airbox just on a rainy day let alone if you happen to go through a creek crossing type bridge like ESKY has the photo's on on the forum! Very scary!

2) The airbox is pressurized through the standard air duct from under the bonnet into the airbox at speed! From thinking about your mods it would appear that you may loose alot of that advantage. Each his own

very nice looking job but I think all you may have done is increase the intake noise! Nothing wrong with that!

[geea]

I have a couple of concerns about your mod!

1) The placement of the intake at the bottom of the the bumper! It will suck an awefull lot of water up into the airbox just on a rainy day let alone if you happen to go through a creek crossing type bridge like ESKY has the photo's on on the forum! Very scary!

2) The airbox is pressurized through the standard air duct from under the bonnet into the airbox at speed! From thinking about your mods it would appear that you may loose alot of that advantage. Each his own

Harasn, if I were to shorten the length of the pipe by 20-30cm so it sat above the driving light; do you think that would solve the concerns regarding the water?

Regarding your 2nd point at some stage I'll have another go on the dyno in Melbourne and compare the result with last time and if nessecary make some changes.

Thanks for the comments, I really appreciate the feed back.

Now can someone organise another Melbourne dyno day. :D