Homemade 6" Air intake, AKA the "whistler", tech write-up
 

Here is a little homemade air intake tech....

I have been searching around for the best intake and it seems everybody loves the AFE stage 2 system, so when I started gathering parts for mine I tried to find out what made the AFE 2 whistle so much more then the rest. The only difference I could find was the 6" air filter inlet on the AFE 2 verses the 4" filter inlet for the rest of the aftermarket intakes S&B, airaid etc. That's what I went after is a 6" intake.....

The design is very simple, I welded my IAT sensor mount to the aluminum but if you don't have access to a TIG welder then there is an alternative that I will explain in a few. I also rolled my own tubing so I did not have to buy any tubing, but I included part numbers for those who don't have the tools to do this.


here's the parts list.

1. 1 amsoil cone filter part#EAAU6080 MSRP $66.70
2. 1 rubber 90* intake adapter part#90L60R55 90*x 6" x 5.5" $26.61
3. 1 8"-6" length 5.5"OD aluminum tubing $12.63
4. 1 4"-6" length 6"OD aluminum tubing $8.71

* since I did not buy tubing I made my whole intake for $85 bucks*

here's where to get them,

1.https://www.amsoil.com/storefront/Se...CategoryID=346
2.http://intakehoses.com/Merchant2/mer...ory_Code=R9DEN
3.http://intakehoses.com/Merchant2/mer...gory_Code=SIT7
4.http://intakehoses.com/Merchant2/mer...gory_Code=SIT7

you can also find parts here but they are a little more $$$
http://store.airflo.com/



This is what you end up with...
https://www.dieseltruckresource.com/...m/DSC_0086.JPG

The black piece is the 5.5" tube and the other non-painted piece is the 6"
I reused the factory turbo elbow because for some reason the places I found wanted $60. bucks for that adapter for some reason??



I welded a thick piece of aluminum on my 6"OD section so I could reuse the IAT sensor. It you don't have access to a TIG welder then I am pretty sure you could just drill it into the 90* rubber elbow, the rubber is so thick it would work just fine to drill a 1/2" hole in the rubber and mount the sensor that way.
https://www.dieseltruckresource.com/...m/DSC_0089.JPG


Nice filter too...
https://www.dieseltruckresource.com/...m/DSC_0093.JPG

shot of the adapter....
https://www.dieseltruckresource.com/...m/DSC_0099.JPG


nice and smooth inside.
https://www.dieseltruckresource.com/...m/DSC_0098.JPG
6" Baby!!!
https://www.dieseltruckresource.com/...m/DSC_0097.JPG
here it is installed!!
https://www.dieseltruckresource.com/...m/DSC_0102.JPG
nother installed shot..
https://www.dieseltruckresource.com/...m/DSC_0108.JPG
the tube and elbow get pretty close to the exhaust manifold but I have been running this intake for over a week and it NEVER even gets warm to the touch!!
https://www.dieseltruckresource.com/...m/DSC_0107.JPG
I turned my battery cable to get a little more space..
https://www.dieseltruckresource.com/...m/DSC_0106.JPG
I have be running this set-up for about 1 week and I can tell you I LOVE IT!!!!!
I had a BHAF on my 01 and it puts the BHAF to SHAME!!!! as soon as the engine hits 1000rpms the turbo just starts singing, music to my ears. even when I turn on my high idle it singes.
My buddy DTR member "DEAVY HUTY" has an Airaid intake on his 05 and he wants to sell it and put on my intake because it whistles sooooo much!!

I know the AFE2 has a box so stay tuned because next I will be doing the box...

saved for later when I make the box....:cool:

Nice work! I wish I knew how to weld then I could make some neat projects.

Anyhow, what is the flow specs on that filter? cfm @ x" etc ?

Also, does that filter have an inverted filter cone on its end?

-Thanks-

Great write-up!!! I think I'm gonna use a little christmas $$$ and do this. I'll post pics and updates soon. Thanks 53!!!![guitar]

I don't know the CFM spec on this filter, I was going to call amsoil tech to find out.
Amsoil did not make a 6" filter with an inverted cone top...:(
If your not an amsoil dealer it may be cheaper/better to buy JUST the replacement AFE2 filter.
If your an amsoil dealer the filter I bought is cheaper then MSRP I listed.....

I went ahead and ordered everything including some T-bar hose clamps[guitar] . Can't wait to put it together!! It cost me a little more (like 140$), but thats shipping, taxes, and everything. Nice little project for the weekend. I hope it whistles!!!![whistle] [whistle] [whistle] [guitar] [laugh]

OK---SORRY----- I would like for Willy's to give me one for a late Christmas present!!!! Right, Willy's [coffee] !!!!!!????

I would like him to make me one. I am pushed for time these days.

Thats a nice job. I fab up lots of my stuff and I like what you have done.

O-yeah it will whistle!!!!:cool: [guitar] that's still not a bad price to build this huge intake.


make sure you post up on the results!!! pic's too if you can.:cool:


53
Mark

It's in the mail...........[coffee]



Thanks!!!:cool:

So whats the alternative to welding for mounting the IAT?

Looks nice.

is it louder than the K&N FIPK?

I gave my FIPK away yesterday - it was TOO loud - esp on road trips.