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Old 02-06-2003, 07:43 AM   #1
clsmooth71
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Wink Just Installed NEW Intake Pipe for Stock Airbox--from CLsports!

EDIT: Per requests, added installation instructions & parts included in the system. Please scroll down and see my reply several posts down.

Hey all,

Well, I just finished installing a CLsports intake pipe for the stock WRX airbox. It's basically like the ZEROSPORTS offering, which replaces the stock, "accordion" pipe. The system consists of a polished aluminum, mandrel bent section of piping, a couple of silicon fittings, and four hose clamps to secure the pieces.

I'm not sure if my butt dyno is deceiving me, but there seems to be a noticeable improvement in throttle response and mid to top end power. I doubt there's a huge HP increase, but my car definitely pulls harder.

CL
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Last edited by clsmooth71; 02-06-2007 at 08:15 AM.
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Old 02-06-2003, 10:23 AM   #2
vile
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nice job.....always luv a good do-it-yourself-er
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Old 02-06-2003, 10:37 AM   #3
Egan
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Cool idea. What size piping did you use and what kind of connectors (looks to be like Samco hose)?
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Old 02-06-2003, 10:39 AM   #4
mdot
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Isn't the MAF sensor supposed to be there somewhere? does this pipe mess with the sensor like they say a full CAI does?

edit...never mind. I took a closer look and found the sensor in line before the new pipe. so it shouldn't be affected.
cool
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Old 02-06-2003, 03:36 PM   #5
xstar
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man, I hate the California car shine.

My wagon is a salty white-blue with dirt right now.

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Old 02-06-2003, 03:49 PM   #6
cavymeister
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Quote:
Originally posted by Egan
Cool idea. What size piping did you use and what kind of connectors (looks to be like Samco hose)?
Yeah! What size and where did you get the piping?
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Old 02-06-2003, 05:08 PM   #7
PaulRex
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Yes mroe info.! Where can I buy an pipe like this, and what dimensions did you use for it?
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Old 02-06-2003, 05:28 PM   #8
djerickd
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when are you gonna start selling these?
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Old 02-06-2003, 06:59 PM   #9
clsmooth71
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Smile Thanks & More 411

Quote:
Originally posted by vile
nice job.....always luv a good do-it-yourself-er
Thanks for the kind words, Vile and everyone. I know the intake isn't as pretty as the full blown, chrome ZEROSPORTS or other intakes on the market, but I always get more satisfaction from DIY mods than putting on pre-fabbed ones.

I was actually looking to buy the new Samco piece that a couple vendors just advertised but figured I'd take a whack at making my own first. Although I guess I won't be entering any shows, unless I do badge the unit as a CLsports piece!

Anyways, here's the parts & dimensions of the parts I used to make the intake system:

1. Piping: Polished aluminum, approx. 5.5" in length, 3" inner diameter, w/straight end/cut on inlet from stock airbox/mass airflow sensor, & slightly mandrel bent end outlet. NOTE: The piping is a section from an old, RS Akimoto intake for a '90-93 Integra I had collecting dust. I just took off the stock WRX intake hose & lined it up w/the RS Akimoto piping. Fortunately, I was able to match the stock unit's bends w/part of the Akimoto's (mid section w/the breather hose fittings, which I capped off).

Btw, I didn't have a power saw or other cutting tool, so I "cut" the piping using a method I saw in an OPTION Magazine. I drilled a series of holes around the circumference of the piping & used a pair of metal snips to separate the sections & trim the burrs off. IT TOOK ME FOREVER!!! I NEED TO GET A SAW!!

2. Silicon Coupling (Airbox/Mass Airflow Sensor to Intake Piping Inlet Connection): approx 2" in length & 3" inner diameter

3. Silicon ***REDUCER*** Coupling (Intake Piping Outlet to Engine Connection): Approx 2.25" in length & 3" to 2.5" inner diameter. NOTE: It's IMPORTANT to use a reducer coupling because the intake piping diameter is larger than the fitting to the engine. The reducer fitting ensures a more secure connection & minimizes gaps and/or binding of silicon coupling.

4. Hose Clamps (4) to secure fittings/connections of pieces (You only need 2 more, since the stock intake pipe already has 2).

TIPS:

***It IS NECESSARY that you use piping w/a bend on the outlet end (preferably mandrel bent to ensure smooth & max airflow). The bend facilitates installation of the piping & coupling to the engine fitting & promotes a direct airflow path.

***After installing & removing the system several times, I found that it's easier in BOTH situations to work w/ALL of the clamps fully loosened. Tighten the clamps down after positioning the piping and silicon couplings because the connections are VERY snug even w/out the clamps.

I am currently running the system w/the stock, underhood airscoop & fenderwell snorkel/resonator removed. I also have a drop-in K&N filter.

Previously, I had an air horn from an HKS Powerflow intake mounted in the stock airbox's inlet (in fenderwell). I've removed the air horn and am considering running a length of flexible, dryer hose from the air inlets on the corner of the passenger's side bumper to the airbox. I used a similar system on my old non-VTEC 90 Integra and achieved EXCELLENT results. (high 14's w/only a header, catback exhaust on street tires & FULL interior...Man, I miss terrorizing guys w/that low-buck brawler!)

Anyways, I think that's it. If anyone needs further instructions or has questions/comments, hit me up

CL

Last edited by clsmooth71; 02-06-2007 at 08:16 AM.
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Old 02-06-2003, 07:28 PM   #10
clsmooth71
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Quote:
Originally posted by mdot
Isn't the MAF sensor supposed to be there somewhere? does this pipe mess with the sensor like they say a full CAI does?

edit...never mind. I took a closer look and found the sensor in line before the new pipe. so it shouldn't be affected.
cool
Yeah, the intake pipe is downwind (after) the MAF sensor, so I don't think there are any adverse effects on the sensor or stock computer. I took this into consideration before I started the project. Hopefully, I/we are right!

The aluminum piping is slightly wider in diameter & MUCH smoother than the stock, rubber, intake pipe. The stock unit has several ribs, which in my thinking, obstruct airflow.

CL

Last edited by clsmooth71; 02-06-2007 at 08:16 AM.
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Old 02-07-2003, 09:55 AM   #11
Egan
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CL,

Where did you get the silicon hose couplings from? Is this something you can find at a local auto parts store?

Again, great idea!
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Old 02-07-2003, 11:55 AM   #12
AZScoobie
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Default Re: Just Installed NEW Intake Pipe for Stock Airbox--from CLsports!

Quote:
Originally posted by clsmooth71
EDIT: Added installation instructions & parts included in the system. Please scroll down and see my reply several posts down.

Hey all,

Well, I just finished installing a CLsports intake pipe for the stock WRX airbox. It's basically like the ZEROSPORTS offering, which replaces the stock, "accordion" pipe. The system consists of a polished aluminum, mandrel bent section of piping, a couple of silicon fittings, and four hose clamps to secure the pieces.

I'm not sure if my butt dyno is deceiving me, but there seems to be a noticeable improvement in throttle response and mid to top end power. I doubt there's a huge HP increase, but my car definitely pulls harder.

Here's a couple of pics of the system. Please excuse my plain Jane & dirty engine bay!

http://photos.yahoo.com/bc/cyaintegr...Intake&.view=t

CL

Btw, if you guys didn't catch on, I MADE the intake myself!
Cool idea. Just fyi. The zerosports unit's instructions instruct you to remove the bolt that holds the turbo inlet pipe to the manifold. This way you do not crack the pipe when the motor trq's over. Its the single bolt on top of the inlet pipe behind the wire harness. I did not remove mine completely. Just loosened it up and that gave me alot of wiggle room.

CT
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Old 02-07-2003, 06:39 PM   #13
Dakken
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how much did this cost ya, total?
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Old 02-07-2003, 06:54 PM   #14
clsmooth71
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Arrow Silicon Couplings

Quote:
Originally posted by Egan
CL,

Where did you get the silicon hose couplings from? Is this something you can find at a local auto parts store?

Again, great idea!
Egan,

I scavenged most of the parts from the 90-93 Integra intake I had laying around. I checked the auto parts stores near me and none of them had silicon couplings. A couple had rubber ones but not the pretty, colored stuff! Your best bet would be to check out your local tuner/speed shop.

Hope this helps,

CL
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Old 02-07-2003, 06:58 PM   #15
clsmooth71
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Default Re: Re: Just Installed NEW Intake Pipe for Stock Airbox--from CLsports!

Quote:
Originally posted by AZScoobie


Cool idea. Just fyi. The zerosports unit's instructions instruct you to remove the bolt that holds the turbo inlet pipe to the manifold. This way you do not crack the pipe when the motor trq's over.

CT
AZScoobie,

Thanks for the tip. I did read about the recommendation to loosen the bolt after I installed my system (was searching for ZEROSPORTS intake pics to compare w/mine). I'll definitely go down to the garage and look for the bolt to loosen. The system has almost NO free play, so I was concerned about busting the rigid, stock inlet pipe.

CL
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Old 02-07-2003, 07:13 PM   #16
clsmooth71
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Arrow FREE!!

Quote:
Originally posted by Dakken
how much did this cost ya, total?
I'm in good w/the CLsports organization, so I got the system for free! Seriously, I just took most of the parts from my old 90-93 Integra intake.

If you were to build the system yourself, I'd say it'd run you....

***(2) Hose Clamps (need 4 total, but 2 come w/stock pipe): $3-4 @ Home Depot or auto parts store

***(1) 3" Diameter Silicon Coupling: $5-15 @ your local speed shop/aftermarket accessory store

***(1) 3" to 2.5" Diameter Silicon REDUCER Coupling: $10-$15 @ same source as above coupling

***(1) 3" Diameter Section of Pipe w/a Bend (preferably thin wall, aluminum & mandrel bent, but you can get away w/regular, "crush bent" pipe from a muffler shop. Just bring your stock intake pipe & telt them to match it, BUT make sure to have them make the pipe shorter to accomodate for the silicon couplings. The stock pipe does not use any additional fittings): $20-30

TOTAL: $64 MAX!! You can probably do it for a lot less. I just went high on the estimate.

If you guys have the time and are even a little, mechanically-inclined, building this system is well worth it! I detect better throttle response & mid-top end pull, but don't expect MONSTER HP increases. You can anticipate more BLING under your hood though!

Good luck!!

CL

Last edited by clsmooth71; 02-07-2003 at 07:55 PM.
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