I have been running the K&N version of the stock air filter. My turbo recently showed how much its bearings were worn and with the subsequent removal, I found what I think is impact damage to the leading edges of the compressors impeller.

The BHAF's pleated filter media will certainly take care of that. My concern with the BHAF is that I've not found a mount that would exclude the hot, under-hood air. It's my understanding that, as a general rule, with every 10 degrees temp drop in the charge-air, there's roughly a 1% power increase across the board.


I need to fix that.


I took a standard 33 quart stainless stock pot that was as tall as the BHAF plus a little, and was big enough in diameter to hold the BHAF while still allowing room for good air flow.:




This is the filter I'm using ( I got it from these guys). ;




I had to shorten the pot so it'd fit the filter, plus room for some gasket material. I did so by cutting it to the right hight, and using some HVAC sheet metal shrinker's, corrugated the tube so that it would plug-in to the bottom.;





Some rivets hold it all together.;





Now's the fun part. I added a duct that would expose as much of the air filter to a good-sized opening to outdoor air. I used the sheet metal that is used in making the seamless gutters as it was heavy enough for rigidity, yet still be reasonably workable. It took a few minutes and a number of cardboard templates to figure it out.;

 

The filter element is offset some so as to allow the incoming airflow equal opportunity to get to all the filter media without undue restriction. It'll also help give the turbo feed duct room to get past the radiators reservoir.;





Having said that, the hole in the lid is cut off center.;





So this is what we have so far.;





With that, we can now add some 3/8" thick Rubatex sheet insulation for gasketing, a couple of L-brackets for the filter to sit on when installed, and some SS spring loaded clips to hold the lid on.;





It's now ready to install.;

 

Now to be fair, I did have to grind away any high spots of the front bulkhead so as to allow the duct flange to fit well against the bulkhead. I also found it helpful to dimple the fender well to give a little breathing room. ;





I cut a number of holes in the front bulkhead so as to allow good air flow without substantially weakening the bulkhead.;





With all that, there's plenty of opening for good air flow. ;





It's kinda hard to see, but with the lights in place, there's ample room for good intake behind the grill.;





Finally, I did have to move the radiators reservoir toward the radiator 1/2" to allow reasonable room for the cold air box. The only problem that I see is I'll have to remove the reservoir to change the filter. Oh well. That boy's in there like a hair in a biscuit! ;







The boxes from PDR show up tomorrow. After installing all that, It ought to flow big-time!


And hey . . . . . it's dish washer safe.


I'll let you know how it sounds.

 

very nice job

 

Good work and nice write-up!

I'd like to fab something different from the general Smoky mount I have now.

I don't have a front valance on my truck though, so the factory scoop is getting a direct shot of air between the radiator and the grill.

Den

 

Pretty shnazzy.....

 

BEST dern use of a stock pot I ener herd of....... give this man a standing ovation!!

VERY WELL DONE INDEED!!!!!

 

Very creative--keep us posted on how it sounds/works

 

absolutely ingenious! this should go into the tech facts. now all you have to do is update your sig. from modified stock box to modified stock pot

very cool

 

Looks really cool. 'Pun intended' I even like how it has a chrome look to it. Just think, come thanksgiving time, you should be all set for the turkey also.

 

Stainless is cool. Nice job!

 

Outstanding! very nice craftsmanship, do you have any detailed measurements or did you "eyeball" the ductwork?

 

Absolutely awesome.

 

That's great! I gotta make me one of them in time for summer.

 

Thanks folks.


Shiny is nice but it ain't no count if you don't have something to pull air through it.



. . . . . . . . . .











I've got to get busy!