Custom Intake System..

[1BADJK]

Here is a couple pictures of the intake system I have created.. Compared to AEM it produces more power and torque.. Dyno Proven

AEM Intake System = 7-8 hp and 4-5 TQ = $250

Custome K&N System 8-9 HP and 6-7 TQ = $75

Obviouslily it just easier for most to just buy a bolt on But if you got some mechanical know how... It not only saves you money but gets better results..

Break down-
K&N Filter RE-0910 ,, Prefilter Wrap RE0910PK = $55
Diesel 90 degree Boost tube = $8
Scrap 30 Degree 3" Exhaust pipe = Free at most shops..
Steel for box $10 1x3 foot 16 gauge sheet metal.. Aluminum

http://photos.oggslife.com/albums/userpics/10001/intake1.jpg

[SpudRacer]

Nice job, looks very professional.

Tom
Bryson City, NC

[tolh13]

Looks good and love the price.but you got me thinking about using most of the stock parts.like cutting up the air box(top) and keeping the stock tube?just need the k@n filter and may be a short piece of pipe.what do you all think???

[papabear]

thanks for sharing. Papabear:yup:

[wayoflife]

Wow, that came out great!! Now you've got me really thinking about this :yup:

[2k2wranglerx]

Looks good and love the price.but you got me thinking about using most of the stock parts.like cutting up the air box(top) and keeping the stock tube?just need the k@n filter and may be a short piece of pipe.what do you all think???


don't do it, or you'll pay more for a stock box on ebay/forums later if you want to put it back to stock or add a snorkel!

[Robar]

This set up uses the stock box, and tube with an extention on it for the length and pvc hose. It is $40 without the filter.

https://rustysoffroad.com/Merchant2/media/performance/jk-at_01.jpg

[2k2wranglerx]

This set up uses the stock box, and tube with an extention on it for the length and pvc hose. It is $40 without the filter.

https://rustysoffroad.com/Merchant2/media/performance/jk-at_01.jpg

careful with PVC. i've heard it gives off gasses that can damage your engine when introduced to heat.

[1BADJK]

Just so everyone knows the whole point in creating an aluminum box is to isolate the Radiant heat the motor creates.. This allows cold air from the front of the vehicle to enter the boxed in area and keeping the heated air around the motor out.. Thus creating more efficent power from the motor.. Getting rid of the Stock intake hose is 40% of your gain.. The stock hose creates the unwanted turbulance..

Never use PVC.. Creates Detonation within the motor.. Very bad.. When PVC is heated over 180 (edited) degrees it releases very dangerous fumes..

[FRDesign]

You should make a write up on how to make it!

[ericdewayne]

totally agreed! A write up on your little project would be great.

[tolh13]

Just so everyone knows the whole point in creating an aluminum box is tthe Radiant heat the motor creates.. This allows cold air from the front of the vehicle to enter the boxed in area and keeping the heated air around the motor out.. Thus creating more efficent power from the motor.. Getting rid of the Stock intake hose is 40% of your gain.. The stock hose creates the unwanted turbulance..

Never use PVC.. Creates Detonation within the motor.. Very bad.. When PVC is heated over 80 degrees it releases very dangerous fumes..

Thanks.i agree with intake hose and you make it sound easy but its the box thats seems like the hardest and most work so i was just looking for a short cut to modify the stock box but keep the hot air isolated.and thanks for all your info.

[papabear]

You should make a write up on how to make it!

I very much concur, if you have done this 1BADJK you should do a write up. By the way Very NIce JOb. Papabear:yup:

[jdrogers]

... Very bad.. When PVC is heated over 80 degrees it releases very dangerous fumes..

I'm thinking you're missing a digit there somewhere... If PVC released "dangerous fumes" when heated over 80 degrees, just about everyone round here in Arizona would be dead in the summer. I can pretty much guarantee it handles 110 or 120 degrees without any problem. :)

Maybe somewhere around 800 degrees it might release fumes...

[inlo]

Since I'm on a strict budget (per wife), I used some parts I had lying around from a MAC mustang gt cold air intake(CAI) to make my JK CAI. I left the stock lower part of the air box in place (to help block water and hot air) and just took off the top and tube (in case I need it later). I know you can buy similar parts off e-bay for about $45 shipped to your door. The intake along with exhaust mods has made quite a differnce in the JK powerband. I saving up to spend some money when the ECM programmers come out .

[2k2wranglerx]

Since I'm on a strict budget (per wife), I used some parts I had lying around from a MAC mustang gt cold air intake(CAI) to make my JK CAI. I left the stock lower part of the air box in place (to help block water and hot air) and just took off the top and tube (in case I need it later). I know you can buy similar parts off e-bay for about $45 shipped to your door. The intake along with exhaust mods has made quite a differnce in the JK powerband. I saving up to spend some money when the ECM programmers come out .


I have some honda cold air intakes laying around. I'll probably end up doing the same thing!

[1BADJK]

I'm thinking you're missing a digit there somewhere... If PVC released "dangerous fumes" when heated over 80 degrees, just about everyone round here in Arizona would be dead in the summer. I can pretty much guarantee it handles 110 or 120 degrees without any problem. :)

Maybe somewhere around 800 degrees it might release fumes...

Your correct. Sorry about that.. 180 Degrees.. I will post the link on PVC vs. Automotive.. Just have to find it again...

[nader]

Can you post the dyno sheet comparing the two? I'd like to see how it affects the entire powerband.

Nader

[1BADJK]

I will post before and after Dyno slips by this weekend.. Busy week..

[Mudjocky]

I'm curious about the pvc being dangerous to the engine....since pvc hoses have been used for emissions hoses for years, and even the plastic valve covers are made of pvc...as are many of the elbows used in pcv/ccv valves. I've ran pvc for over ten years in my YJ with no problems at all.........please post the link.

[Steve&2jc's]

I'm curious about the pvc being dangerous to the engine....since pvc hoses have been used for emissions hoses for years, and even the plastic valve covers are made of pvc...as are many of the elbows used in pcv/ccv valves. I've ran pvc for over ten years in my YJ with no problems at all.........please post the link.
Oh no, you're over here now too.

[2K1TJ]

Here's mine....
Integral, insulated heat shield, Apexi dry filter inside, Velocity stack inlet..

http://images19.fotki.com/v381/photos/7/7305/4465453/IMG_1079-vi.jpg

http://images20.fotki.com/v385/photos/7/7305/4465453/IMG_1093-vi.jpg




I like this setup. Where did you get these parts? I'm assuming you pieced this together and it's not a kit, right? I'm leaning towards a dry filter but don't want to pay over $200 for an AEM kit.

[Cesar]

A write up would be great

[mobotix]

Since I'm on a strict budget (per wife), I used some parts I had lying around from a MAC mustang gt cold air intake(CAI) to make my JK CAI. I left the stock lower part of the air box in place (to help block water and hot air) and just took off the top and tube (in case I need it later). I know you can buy similar parts off e-bay for about $45 shipped to your door. The intake along with exhaust mods has made quite a differnce in the JK powerband. I saving up to spend some money when the ECM programmers come out .

What year Mustang was the CAI for?

Thanks

[mobotix]

Just to let you guys know. The 99 - 04 MAC Mustang CAI tube mated to a K&N RC-5040 works amazing while leaving the bottom half of the stock air box. I will try and post pics asap, but the same setup can be found on the second page of this post. All in all, I got all of the parts for around $60. I got lucky and found the MAC on ebay for $22.50 shipped and the filter on Amazon marketplace for around $40.

[sgmrock]

Very nice setup. I already bought a kit for big bucks, oh well...