So, I bought my 2004 JCW about 8 months ago and it came with a K&N Typhoon. I thought cool, a CARB legal intake. But, after looking at it more and reading a lot on these boards, I came to the realization that I can do much better. Primarily to get a “box” type CAI, to help keep only colder air entering the intake. However, living in California, CARB is a big deal to me since the SMOG guys almost always look at intakes for CARB approval first.

So, what to do? Spend money on a new intake system and save the CARB K&N for SMOG time? Well, to be honest, a lot of the intakes I had seen pretty much look like a filter in a box and even utilize the existing intake tubes and routes. Plus I liked the dual red intake tubes of the K&N Typhoon. So, I set out to create my own and utilize the K&N Typhoon. Below are some pics of the progress and completed product. Hope you all enjoy.

First, a pic of the original K&N Typhoon installed. Notice the openness of the original system. I can only imagine it was pulling hot air from the engine bay only. (No cowl mod done, yet!)


Second, a pic of the first of the two part system to enclose both intake tubes. (Unpainted)


Third, a pic of it painted. (I have only used rubber dip paint right now, but will eventually find some heat resistant type paint.)


Fourth, a pic of the first part installed. Notice the new extension for the front air inlet part of the dual intake tubes.


Fifth, a pic of the second part of the system. The “box top”. (Unpainted)


Sixth, a pic of the finished product. Also, while I had the intake out, I took the opportunity to cut a few holes out to open up the cold air path from the cowl.


Seventh, a pic of the new air box, and its new neighbor. A new DFIC.


All in all, it took quite a long time to finish this project and I probably could have bought a newer one and just installed it. However, I only paid about $45 for material and a few minor tools not counting the K&N Typhoon. And, I get to keep the CARB sticker.

Now, what to work on next???

Thank you,
JBravoMC

 

Job well done!

 

is that aluminum?

 

Where did you get that?

 

I like it!

Nice job.....

 

Ah, did you read the thread? He made it.

Very nice work! It deffinitly looks like it "belongs" there, and really fits in well.

-Cody

 

Very very nice! Looks like I have a template for my project now. Thanks!

 

up Bravo. Well worth your effert.

 

Very, Very Nice

 

Yes, excellent work! I like the ideas and the execution is quality stuff. Like me, you executed on a principle--which may or may not actually produce real temperature reductions to the cylinders--and it looks good, too.
I'd like to see some temperature readings, but I know they are very hard to obtain!
Good luck with your next project.
cheers,

 

Nice Job!

 

Very nice and very well done.

 

Looks great. Great job of metal fab.

I am in CA also, and a K&N Typhoon owner for the same reasons you have indicated; so, I'm very interested in the results of the box.

Did you install the DFIC at the same time? before? or after the box? If either after or before, did you notice a difference in either the noise or the performance with JUST the box installed?

Last, did your work products happen to include an actual template ("blueprint") of the box and lid pieces that you fabricated?

Thanks!

 

Job Well Done

 

Love IT!

 

Excellent job!!

There is a pretty decent amount of air coming through that front duct the way it is, but the air has to find it's way there. Maybe your next project could be to make an extension that extends down behind the grille.

 

Thanks everyone. Let me try and answer some of the questions.

Yes, it is made of Aluminum. I will be reproducing it again in something more fitting for an intake box to keep the heat out. And also a little bit of a re-design after some pondering of the final product. Better sealing to the tubes, more simple design, etc...

I do have some templates that I made to fab this, but they are not really complete. I did some tweaking in the buld process as the templates weren't quite up to snuff. Once I re-design it though, I will more than likely keep the templates and give them to anyone who wants them.

I did install the DFIC at the same time. I opened up the back panel behind the intake into the cowl under the window and that produces a little more whine, which I like. Other than that, no real big change in sound. Also, with having done both at the same time, I cannot tell if the box is really "helping" much but I can't see it as hurting.

PARTSMAN, I like the idea. I may look into that a bit more in the next version.

Thanks again,
JBravoMC

 

THis is exactly where I find myself! I can't see any of my fresh air mods hurting, other than taking away some air from the DFIC, which I need to test soon. I also can't seem to feel any difference and certainly can't measure it since I only got my instruments recently.
I am *thinking* about reverting to the stock IC just for giggles. I've decided that TE is interesting but ultimately it's the IAT that is important. If I can get colder higher pressure air into the cylinders, my goal is achieved.

Keep up the great work!

 

Great idea and execution!

 

What type of equiptment/tools did you use to do the metalwork? That is a professional qualiity job!

 

Joe,

A Hammer and workbench for bending the metal, some pliers, rivets, a dremel to smooth out the coners, and a hole saw for the tube openings. Oh, and some tin snips to cut the metal.

Thanks for the compliment on the quality.
JBravoMC

 

Where the heck do you people take your car to get smogged? Nobody ever looked at anything other than the results on any car I have ever smogged in California. I could have anything I want going on under the hood as far as the smog monkeys care.

 

Not too shabby dude Nice work

 

How much air do think the K&N takes from that hole on the bottom front to the engine bay? Ever think about plugging that up or is it necessary?

 

looks pi$$a!!!