DIY Cold Air Intake
 

This is a good DIY project if you have some basic tools and want to give it a go. I did this several years ago after reading a similar how-to that Dan Pilo wrote.

I started by mocking up the heatshield using thin cardboard. I used modeling clay to determine the height that the heatshield needed to be.

https://www.northamericanmotoring.co...n_P6210013.JPG

I made a second cardboard mockup to check the fit of the final design. Once I was happy with the fit, I made a master template to make it easier to transfer the outline.

https://www.northamericanmotoring.co...n_PC280040.JPG

I used a jigsaw with a metal cutting blade to cut the basic shape. I then drilled the mounting holes and the hole for the intake tube as it's a lot easier to do this on flat material.

The next step is to bend the flat sheet to it's final shape. I used 2 pieces of angle iron and a shop vise to make the bends.

https://www.northamericanmotoring.co...n_PC280039.JPG


This shows the final shape.

https://www.northamericanmotoring.co...n_PC280044.JPG

Here's a group photo.

https://www.northamericanmotoring.co...n_PC280045.JPG

The hole for the intake tube will vary depending on the size tube and filter you use. The stock rubber tube will accept a 2 5/8" OD tube. If you are using a Alta silicone tube you can use a 2 3/4" OD tube. I used a 2 3/4" OD by 2 1/2" ID aluminum tube with one end machined down to 2 5/8" to maximize airflow.

Here is a drawing of the flat pattern for the heatshield.

https://www.northamericanmotoring.co...HEATSHIELD.jpg

This was a fun project to do. My costs were as follows.

Aluminum sheetmetal $0
Aluminum tubing (2') $40
Rubber seal (20') $20
K&N filter $60
Total cost $120

Saved $80 over typical intake. I sold several heatshields to cover the material costs so it really only cost me some of my time.:thumbsup:

NICE :thumbsup:

Nothing like rolling up one's sleeves. I especially like the made a few extras and re-cooped my costs :nod:.

Thanks for sharing

Thanks Bahamabart.

GREAT!!! :thumbsup: Hate 'off the shelf' stuff (except of hard-core tech stuff)! Maust have, must make!

What software did you use to make the drawing? Is there any way you could let us download a PDF or similar?

looks like it's made in Auto CAD to me

oh by the way, that's an amazing job! :thumbsup:

Hi,
I just 'threw it' in the Corel and it is more than enougth to have a accurate drawing. :)

Hi sanddan,
Any chance to tell us the exact position and diameter of the hole? :) Everything is so precise so...
TNXaLOT!