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For those of you who are interested in my "homemade" intake:
Sorry for the length, I thought it best to be detailed and not vague, also
expect to spend a good day working on your intake.
materials needed: (everything can be found at autozone and/or a plumbing shop)
-sensor safe high heat sealant (for the choke sensor)
-pvc cement and pipe prep treatment
-one section of 3inch id pipe (interior diameter) the larger the overall size
of the pipe the better the insulation from the engine heat so I'd say
go as large as possible with weight and space in mind (I used 3 1/2 outside
diameter pipe) I cut the pipe to somewhere right around ten inches
-2 45 degree elbows (male end-3 inch id the other end female-3 1/2 inch id)
-A thick piece of plexiglass (1/4 inch thick by about 6 inches square)
-Additional caulking/adhesive type stuff (Goop brand)
-Drill with 5/8 inch bit
-A round file or maybe sandpaper (to smooth any rough edges to improve air
flow)
-K&N cone filter (60 bucks) part number RF-1016 (note: the rubber mounting
flange is angled at about 10 degrees)
-A lot of patience
procedure:
to make adapter to mount pipe to MAF sensor pipe: cut plexiglass to 6 inch
square and trace MAF sensor gasket onto plexiglass, remove middle with saber
saw and file to ensure free flowing fit to MAF pipe, attach male end of elbow
joint to adapter with pipe sealant and Goop (prior to doing this losely
assemble entire intake to ensure the proper angles- first elbow joint at MAF
then 10 inch section of pipe next elbow joint and lastly K&N cone filter (note
: I cut away some of the road debris gaurd so my filter would sit lower)
once correct angles are assured glue elbow to plexiglass (if lip of pipe is
NOT flat then sand it so it seats squarely on plexiglass, I used a belt sander
)
To make pvc intake: glue together the three pieces of pipe (elbow, pipe,
elbow) make SURE your angles are right so that the filter fits where you want
it, also cut away the plastic flap so the filter can sit lower, now put the
entire assembly in place and use the MAF pipe to mark your holes (note: this
is your last chance to adjust the positioning of the intake by rotating the
plexiglass adapter around the MAF) drill your holes (the upper holes were
really close to the pipe so I used smaller holes for the top 2 screws, also
be sure to use flat washers to spread the force of the screw out against the
plexiglass so it will not break) next drill a 5/8 hole in the intake to mount
your choke sensor (the sensor that screws into the top left corner of the
stock air box) Note: **before you mount the intake and the sensor let the
piping dry for a few hours in front of a fan so the noxious fumes from the
pipe glue don't damage intake sensors.** Lastly screw the intake to the MAF
and stick the choke sensor into the hole you drilled in the intake and seal
it with the sensor safe gasket material. Now start your car and watch for
the check engine light, if it's ok then proceed to mount the intake (attach
it to something under the hood to prevent the intake from shifting (I used
the battery ledge and some exaust strapping) Also check to make sure the
filter isn't rubbing on anything i.e. the plastic debris guard. Now take the
car out for a spin! Also, you may want to paint or cover the pipe with
inusulative foam (available at any auto a/c store) to help keep the intake
air cool for improved combustion.
One last important note: polyvinylcloride (pvc) is highly carcinogenic and
toxic if particles are inhaled so wear a filter if you're doing any heavy
duty sanding on a section of pipe
Will Hauser
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