Ace

The main idea here was to optimize the existing intake without spending a whole bunch of money and shooting for the highest possible cool factor. Total cost in materials less than about $10. All I actually had to buy was the weatherstrip, already had the paint, goop, tape, welding gas, scrap metal, etc. Time spent about 8 hours over two days. This mod would only be recommended for the hardcore DIY'ers with too much time on their hands.

Here's a shot of the rad support pass through opened up:

http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_45.jpg

Air box tube almost finished:

http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_46.jpg

Fascia opening cut and finished:

http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_47.jpg

Enlarged breather tube installed:

http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_48.jpg

Couple shots of the trick piece finished and ready to install:

http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_49.jpg
http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_50.jpg

Final assembly and finished install:

http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_51.jpg
http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_52.jpg
http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_53.jpg
http://66.17.171.114/PhotoAlbum/Cars/Pics/CTD_54.jpg

Works good. Like Jim Lane said, seeing a couple pounds of boost coasting at 70mph. Saw max boot at top gear WOT 20psi. I think it was only hitting 15-16 before. EGTs are down too.

bigragu

Wow! Looks like you took an idea and ran with it! I'm glad that it is functioning well for you! My version only took me about 3 hours only....I opted to just do the hole in the fascia piece(same size as the duct dimensions, and directly in front of the duct) and trim out the hole with door edge molding. I needed that ductless gap between the two in case of heavy down pour. A+ for effort and good job to ya!! Carmyne

BC847

Pretty slick work there!

mhuppertz

Nice going Ace!
I may do something similar with a stock pot BHAF setup.
You rock!

Can you put these pictured on your gallery so Dave can put them in the sticky?

jrussell

Ace, looks good man. Are you still running the stock filter and filter box with that setup?

Ace

I'm not too worried about rain because the intake duct goes uphill into the box, and I'm running a K&N so some water shouldn't hurt it anyway. I may put together a little baffle I can clamp on the brush guard or something if I see any issues with it after first time in the rain. Don't rain much around here anyway.

I haven't been putting pictures of the tech stuff in my gallery cause I run my own server and there's just too many of them. I also post to a couple other forums, so keeping up with the after action processing is becoming a job in itself. It gets tiresome duplicating effort on everything. Also, I can run full-sized high-res pics without restriction from my own little corner of the net. Wanna can download any of my stuff from here to add to the DTR and work accordingly as he sees fit.

Cheers...

bigragu

as soon as I learn to post pics, watch out! My mommie always accused me of being a late bloomer....If I wait a few more weeks and sound all giddy w/ excitement when my pics come through, just remember the mommie thing and don't flame me!

Ace

Drove home in a light rain yesterday, pulled the tubing off the turbo/box right after I parked it and found no water in sight anywhere. EGT was really low too - 550 cruising up the interstate! Will wait for a harder rain and pull the filter next time to see what is actually making it onto the filter. I'm hoping the angle up into the box baffles it enough to call it good with a K&N under just about any circumstances short of being actually submerged.

mhuppertz

I am tempted to go back to the stock air box and do this.... naaa, I like the BHAF too much. Stock pot (with a baffle) here I come!

Bill Tomlinson

You need some shark's teeth to give the opening a little more nastiness. I want to copy yours......... someday! It appeals to my basic cheapness instincts and I already have the k&n. I wonder if an old tuba could be cut down and hung infront of your setup? Just kidding... sort of.

bhoff1175

Anybody use 1/4-20 coupling nuts on the stock filter houseing @ the 3 cover
plate studs thereby allowing 1 inch or so of clearance between the houseing and the cover plate...... You will need to use 1/4-20 bolts instead of the wingnuts.
It should provide more air flow without modification to the houseing.