My DIY Cold Air Box

[jevansio]

Been wanting to do one of these for ages so thought I'd document the process as I know you guys love pics

 

First up pics of the engine bay. I already had a hole cut in the bay where I used to run my intake outside the engine bay. I moved it back into the bay as the filter got manky down there esp with no undertrays on.

 

 

Another reason was the original hole wasn't cut very neatly & this is an opportunity to address this.

 

 

I found some thick rubber with a checkerplate pattern. This is going to hold the end of the cold air feed, aswell as being flexible is easy to work with & fit.

 

Here's a pic of it cut to fit the area the cold air box will cover, I've already inserted part of the feed.

 

 

The entire feed is made of 4" sections of drainage pipe I got from B&Q. The first piece is a 90deg join, I just drew round the end on the rubber checkerplate & cut a hole for it.

 

Here you can see it sweeping down & to the left.

 

 

Next is a 45 deg angle which aligns the end perfectly with the opening in the front bumper. The great thing is these pipes push together like lego and have a built in rubber seal which gives a great OEM feel to the whole setup

 

 

A quick pic looking down showing both ends of the intake feed

 

 

To support the end of the intake I made a bracket to attach it to the bodywork. I used a bracket that is normal used to support the drainage pipe away from walls (it sort of wraps around the pipe & has 2 legs on), and added my fixing (an alluminium plate) to attach it to the body

 

 

 

The last bit was to use a pipe joiner (again from B&Q, all the bits I used could be purchsed from their "drainage section") which flared the end of the pipe open to suit the bumper vent better. It basically looked like a funnel which attached on the end of the 4" pipework

 

A final pic showing what it looks like from outside, pretty subtle

 

 

Will get onto doing the box next, not sure whether to use aluminium sheet or smoked perspex?

Edited March 27, 2010 by jevansio (see edit history)

[Geo]

Nice and Simple Jay.

 

Im sure there will be loads of cold air going into that then, think it will make a diiference though??

[jevansio]

Cheers George, once I get the box made I think it will (esp in the hotter days).

 

It def feels quicker today though, I use my performance box to check the cars performance, midweek it showed 492rwhp, today it showed 506rwhp.

 

The best one was fitting new plugs that went from 470rwhp to 492. So in total the car has picked up 36rwhp from the various things I've fixed/changed over the last week or two (even though the ambient temps have been rising day after day)

[nigelboyne]

lovely work what mileage are you changing plugs

[Geo]

Cheers George, once I get the box made I think it will (esp in the hotter days).

 

It def feels quicker today though, I use my performance box to check the cars performance, midweek it showed 492rwhp, today it showed 506rwhp.

 

The best one was fitting new plugs that went from 470rwhp to 492. So in total the car has picked up 36rwhp from the various things I've fixed/changed over the last week or two (even though the ambient temps have been rising day after day)

 

What the hell is that??

[jevansio]

It's a Racelogic Performance Box, a GPS based device used to do such things as time 0-60, 30-130, 1/4mile (or any thing you want timing), accurate to 0.1sec. Enter the weight of the car & it'll also provide a calculated power figure based on what power is needed to accelerate a given mass at that rate. It's prolly not accurate enough to put against other dyno readings (although it does seem pretty bang on for me considering I was last dynoed at 640 flywheel), but it's great for checking the effectivness of mods against each other on the same car as if it's inaccurate, it'll be the same % out for both runs

[Geo]

It's a Racelogic Performance Box, a GPS based device used to do such things as time 0-60, 30-130, 1/4mile (or any thing you want timing), accurate to 0.1sec. Enter the weight of the car & it'll also provide a calculated power figure based on what power is needed to accelerate a given mass at that rate. It's prolly not accurate enough to put against other dyno readings (although it does seem pretty bang on for me considering I was last dynoed at 640 flywheel), but it's great for checking the effectivness of mods against each other on the same car as if it's inaccurate, it'll be the same % out for both runs

 

Mmmmm interesting, iv still to install RLTC in mine had it sitting for ages, might see about the add on then. cool mate thanks

[jevansio]

Mmmmm interesting, iv still to install RLTC in mine had it sitting for ages, might see about the add on then. cool mate thanks

You don't need RLTC for the PB, it's a totally seperate box, have a look in for sale, Wez has one going

[Brazil]

You write some fantastic threads...! Thanks for taking the time to post it up...!

[Geo]

You don't need RLTC for the PB, it's a totally seperate box, have a look in for sale, Wez has one going

 

Im on it

 

cheers

[jevansio]

You write some fantastic threads...! Thanks for taking the time to post it up...!

Thanks, no probs at all

[devan]

Jevansio; i like how youve mounted your HID Ballast, but how is it secured down, as i cant see the bracket for it?

[jevansio]

Jevansio; i like how youve mounted your HID Ballast, but how is it secured down, as i cant see the bracket for it?

NoMoreNails - on a roll, they're stuck solid

[devan]

Ok good idea lol, ill look at mounting mine there when they arrive, cheers.

[themodifiedkid]

Another quality post to run along side your fmic ducting thread. Nice one mate very informative, im impressed:thumbs:

[Stonkin]

Good work there mate, well done

[Kirk]

You inspire me to copy every last thing you do

 

Thats some nice install mate

[jevansio]

Many thanks guys

 

Made the template for the box yesterday, decided to make it so it can take a lid so it is totally enclosed,

 

I think I'm going to use the aluminium sheet rather than lexan sheet

 

 

[Suprab1]

I think this is going to be a very nice job when finished.

[Mas]

Looking good mate, seems like thats what I need to finish of the cones I have in front of my bumber

 

PLUS: do the headlights fit without problem with your balast fitted there mate?!

 

Ive got 3 on each side and running out of ideas where to put them

[jevansio]

Cheers guys,

 

Sorry for the late reply Mas, the headlights fine perfectly, they actually help make the balast such a snug fit under them they pretty much hold them in place (although I used adhesive to hold them also)

 

Update:

 

The aluminium turned up this week, I still hadn't decided if I was going to make a box that sealed with the bonnet or a fully contained box.

 

I quite liked this one by uk-rich so set of making my own:

 

 

To determine the distance to the bonnet I used my RC car aerial and measured how much it squashed at various positions

 

 

I re-made a card template using this info, but due to the fact I couldn't guarantee an airtight seal (it was rather an unusual shape & the bonnet skin & frame weren't air tight) I went with the sealed box idea.

 

I made each side seperately and will join them with some aluminmium angle later.

 

Here's the main side cut & in place

 

 

 

I reattached the card side to ensure everything was aligned & well

 

 

And the sides taped together & in place

 

 

 

More tomorrow

[Geo]

Nice work Jay. That coupled with the Air intake from underneath should help loads.

[Suprab1]

Fair play, looking very good.

[glenn]

jay, i havent for got you, with regards to meassurments, was called away with work.will pm you tomorrow morning, with sizes.if you still need them

Edited April 1, 2010 by glenn (see edit history)

[jevansio]

Cheers guys,

 

No probs Glenn, TBH I'm going with the sealed box approach so they're prolly not going to be much use to me anyway, I'm hoping to have it finished tomorrow