Home Brew CAI

[Ryans_JK]

Well I'm too cheap to pay $250 bucks for a bent plastic tube, filter and a heat shield......so I decided to build my own. :D

First I got all of my parts from Home Depot and O'rileys.

Not shown in the pic is some vehicle weather striping and a 1" x 1/4" flat bar.



Black duct tape $4
Black trash can $5
3" pipe clamps $1.50 ea
3/4" elbow for the valve cover breather $1.30
3" (swivel style) duct $7
Cone air filter $19
Self taping screws $1 per bag
Weather striping $3 per bag
Flat bar $7
3" angle bracket $1
Misc bolts found in garage free

Total $70 -- but I already had the flat bar in the garage.

For me $63 :D


http://www.duppong.com/gallery2/d/8989-2/April+2007+016.jpg

First start by removing your stock filter box, to include the 3 rubber inserts.

Next start cutting up your trash can little by little checking how it fits. I just did it by eye and marked where I wanted to cut with a sharpie. Everyone will want a different fit so I did not make a template when I finished cutting mine.

Next locate where you want to put the elbow fitting and the hole for the intake tube. Using a 1" drill bit cut the hole for the elbow and screw it in. Then test fit the heat shield and mark where the inlet tube will need to go. Make sure you only use a 2" hole saw when making your next hole so you can cut slats and bend them to secure the heat shield to the intake tube.

Then test fit every thing to make sure yo like the way it fits.


http://www.duppong.com/gallery2/d/8986-2/April+2007+014.jpg

Once you get every thin fitting the way you like it secure it to the plastic piece that the stock intake connected to. I also made a tab on the heat shield to connect to the power steering resivore (sp) and the metal to the left of it for extra support. I then took the flat bar and bent it so it would wrap all the way around the top of the heat shield and used the self tapping screws to secure it. I put the angle bracket under the inlet tube so the plastic heat shield would not flex.

Finally I wrapped the inlet tube with the black duct tape. Mainly so it blends with every thing and to help seal it up. I also put the weather striping on the top to help seal it to the hood and keep as much of the engine heat away from the filter as possible.

The finished product.

http://www.duppong.com/gallery2/d/8992-2/April+2007+020.jpg

http://www.duppong.com/gallery2/d/8995-2/April+2007+019.jpg

I may work on the duct tape job to clean it up a little but other then that I'm really pleased on how it turned out.

[darkrambler]

Great Idea executed extremely well! :jawdrop: Thanks for posting this, you got me thinking now!

Can you come over and do mine next weekend? :grinnyeyes:

[Ryans_JK]

Thanks, I just thought I would share my idea.

[John L]

One of the best boxes yet, great job!!

[duneslider]

Be sure you don't tighten the clamp too tight on the filter or it will bend that thin metal and allow an air leak.

That thin material really worries me. It would be really easy for it to bend enough to cause a leak.

Just some thoughts, what about using some 3" black PVC pipe? It is lots stronger and still easy to work with.

Also, you could buy the rustys offroad airtube (40) then your filter (20) and then make your homebrew shield (which looks really good by the way) and you would still be in the same price range but would have a very durable airtube that you won't have to worry about bending and leaking.

Love the shield though.
Bryan

[clubber]

Great job..........did you notice more power................?

[Ryans_JK]

Yeah I found out what happens when you tighten it down to much, but other then that it is fairly strong. I almost bought the double walled pipe but it was too large in diameter. As far as power gains, I just dyno'd it today and put 165 hp and 198 tq to the wheels. ( I really need a power chip) But as the seat of the pants goes it accelerates much faster and free way passing is much easier now.

Oh yeah I also cleaned up the duct tape job, it looks much better now.

[RedRockJK]

Nice job Ryan!

[PoorDad]

It has been almost a year. Are you still running your homemade CAI? Any problems with durability? Is it still working well?

That is straight McGyver shit!

[RedneckJeep]

This is the kinda stuff that goes down in hot rod greatness. What a great mod done in a very professional way, and all with bargain basement prices. This deserves to go in magazines. Great job!

You know what? If you wanna clean up the taped look, how bout this? Make sure you have the vent pipe turned right, and go have it RHINO LINED. It'll look good and be sealed.

[Jeep-Power]

Great air box on that unit-- :2thumbs:

I want to share my own unwillingness to spend $200+ on one!



The first performance enhancing mod happened yesterday.

I have been reading here that the stock airbox is severly restrictive. Air Raid boasts a 20 H.P. gain with their filter/intake kit! One guy just cut a huge hole in his airbox and noticed a big differnce. So after reading this months JP article about intakes, I decided to take matters into my own hands. :badgrin:

Stock setup
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7323.jpg

I went on a search for one of those aftermarket cone filters and some rubber couplers to use with a nice hunk of 3" S.S. elbow I had. Using it would require adding an additional elbow, but I figured the S.S. will look cool. 1st stop was Strauss Auto. In my opinion, this is a totally useless store, unless you are completely desperate for some sort of cheap Chinese automotive trinkets or it is 9:45PM on a weeknight and you need a fan belt or wiper blades.


Discusted with Strauss, yet again (I haven't bought a thing form there the last 4 times I have gone I there), Pep-Boys was my next destination. I bit the bullet and joined my fellow Sunday shoppers for a game of bump-n-jump on Rt. 22 though Springfield and Union. This section of road is one of my top choices for a Level 10 exercise in practicing patience. Having passed my test with flying colors, I pulled into Pep-Boys and headed in. With a little help, I found the DIY air intake section. I found a few pieces that would work with my hunk of S.S. tube (2 couplers, filter, and addtional 22 Degree elbow [chrome plated plastic, of course!]). My eye then cauge a ratty box on the bottom shelf. It had been raided of all its internal parts except for the tube, filter, and a hunk of dryer-looking hose. My quest was suddenly complete, as I convinced the clerk to sell me just the shiny aluminum tube for $20. So I got out of there for less than $50.

here's what I scored.

filter, tube and coupler(well, atleast it's package)
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7438.jpg
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7439.jpg
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7441.jpg


started by removing the stock system--


tube
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7442.jpg

airbox
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7445.jpg

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7446.jpg



removed
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7447.jpg


This is the incoming air temperature sensor -- that blue thing is a 'thermistor'-- a resistor that changes it's resistance depending on it's temperature. It is located in the air tube, right before the throttle body. Disconnecting it and running the engine will throw a engine code. :D
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7443.jpg


so I fit the PCV to one side of the tube and the air temp sensor to the other --the holes were already there!

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7449.jpg

trial fit, with filter
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7451.jpg

I had to trim the PCV tube--
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7452.jpg

the iar sensor wire was alittle short, so I had to pop off the mount, so that it fit without tension
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7462.jpg


I wanted to do something to help keep the hot air form the raditator out of the filter. I had some white Formica that did the trick. :D
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7454.jpg

done!

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7463.jpg


Performance Report: Well, it certainly has a bit more low end snap! I was worried it was going to be loud and take away form the comfortable stock feel. It does not make any more noise crusing around. It does hiss a little at idle, it whisltles a little at partial throttle (like the 4.0 does, but not nearly as loud), and when I goose the throttle, it has a nice "wwwoooohhhhh" sound-- :D


`


by the way-- here is the throttle body-- it is PLASTIC , has a 63MM straight-through bore without the stepdown the 4.0 had, It is servo controlled (no throttle cable here!)

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7465.jpg

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7467.jpg


What I thought was interesting was that the throttle body has a smaller diameter than the bore of the intake manifold. It seems that a larger bore throttle body will bolt right up-- I'd say 68MM... :-k


`

[britjk]

[QUOTE=Jeep-Power;356646]Great air box on that unit-- :2thumbs:

I want to share my own unwillingness to spend $200+ on one!



The first performance enhancing mod happened yesterday.

I have been reading here that the stock airbox is severly restrictive. Air Raid boasts a 20 H.P. gain with their filter/intake kit! One guy just cut a huge hole in his airbox and noticed a big differnce. So after reading this months JP article about intakes, I decided to take matters into my own hands. :badgrin:

Stock setup
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7323.jpg

I went on a search for one of those aftermarket cone filters and some rubber couplers to use with a nice hunk of 3" S.S. elbow I had. Using it would require adding an additional elbow, but I figured the S.S. will look cool. 1st stop was Strauss Auto. In my opinion, this is a totally useless store, unless you are completely desperate for some sort of cheap Chinese automotive trinkets or it is 9:45PM on a weeknight and you need a fan belt or wiper blades.


Discusted with Strauss, yet again (I haven't bought a thing form there the last 4 times I have gone I there), Pep-Boys was my next destination. I bit the bullet and joined my fellow Sunday shoppers for a game of bump-n-jump on Rt. 22 though Springfield and Union. This section of road is one of my top choices for a Level 10 exercise in practicing patience. Having passed my test with flying colors, I pulled into Pep-Boys and headed in. With a little help, I found the DIY air intake section. I found a few pieces that would work with my hunk of S.S. tube (2 couplers, filter, and addtional 22 Degree elbow [chrome plated plastic, of course!]). My eye then cauge a ratty box on the bottom shelf. It had been raided of all its internal parts except for the tube, filter, and a hunk of dryer-looking hose. My quest was suddenly complete, as I convinced the clerk to sell me just the shiny aluminum tube for $20. So I got out of there for less than $50.

here's what I scored.

filter, tube and coupler(well, atleast it's package)
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7438.jpg
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7439.jpg
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7441.jpg


started by removing the stock system--


tube
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7442.jpg

airbox
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7445.jpg

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7446.jpg



removed
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7447.jpg


This is the incoming air temperature sensor -- that blue thing is a 'thermistor'-- a resistor that changes it's resistance depending on it's temperature. It is located in the air tube, right before the throttle body. Disconnecting it and running the engine will throw a engine code. :D
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7443.jpg


so I fit the PCV to one side of the tube and the air temp sensor to the other --the holes were already there!

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7449.jpg

trial fit, with filter
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7451.jpg

I had to trim the PCV tube--
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7452.jpg

the iar sensor wire was alittle short, so I had to pop off the mount, so that it fit without tension
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7462.jpg


I wanted to do something to help keep the hot air form the raditator out of the filter. I had some white Formica that did the trick. :D
http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7454.jpg

done!

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7463.jpg


Performance Report: Well, it certainly has a bit more low end snap! I was worried it was going to be loud and take away form the comfortable stock feel. It does not make any more noise crusing around. It does hiss a little at idle, it whisltles a little at partial throttle (like the 4.0 does, but not nearly as loud), and when I goose the throttle, it has a nice "wwwoooohhhhh" sound-- :D


`


by the way-- here is the throttle body-- it is PLASTIC , has a 63MM straight-through bore without the stepdown the 4.0 had, It is servo controlled (no throttle cable here!)

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7465.jpg

http://i129.photobucket.com/albums/p228/TallPeter/JK/IMG_7467.jpg


What I thought was interesting was that the throttle body has a smaller diameter than the bore of the intake manifold. It seems that a larger bore throttle body will bolt right up-- I'd say 68MM... :-k

[britjk]

I did mine in November of 2006. Same parts - from AutoZone. Works great.

[Jeep-Power]

How long did you have the JK before you did this? I'm wondering how much difference you noticed.

[britjk]

How long did you have the JK before you did this? I'm wondering how much difference you noticed.
Bought it in October 2006. So say a couple of months. Not sure whether it does anything to the mileage but it sounds good and there's definitely more low end power.

[windnsea78]

Sweet! Maybe you guys could help me run some duct work out to my new sunroom too!:rotflmao:

[Jeep-Power]

Sweet! Maybe you guys could help me run some duct work out to my new sunroom too!:rotflmao:

I'm in if you are buying the plane tickets! :rotflmao1:

[RedneckJeep]

I'm in if you are buying the plane tickets! :rotflmao1:


...and I'm in for plane tickets and free beer.