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Old 01-14-2001, 02:48 PM   #1
Reciprocity
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Arrow My DIY Intake pics (long)

Here are some pictures of the DIY intake my friend and I built. It took a LONG time and a lot of experimenting to make, but it turned out better than we had planned. And although it involved many trips to Tap Plastics we were able to do it fairly easily.

The first step was to make a mold of the intake itself. We used self expanding foam to make a big huge block...then worked on cutting it down, shaving it, and generally fitting it into the shape that would work best. Note: Nothing scientific there, it was just a matter of making it fit!

After that we used fiberglass to make the intake itself. That was actually fairly easy...just VERY messy! We also used dye in the resin to make it black. I still am going to paint it...one of these days.

After it dried we test fitted it again, cut the nec. holes...and slapped it in! How well does it work? It works GREAT! The only intakes I have used have been DIY...but this one was the most ambitious of all...and I am very pleased with the results.

Notes on performance. First of all, it gives a SWEET sound! At WOT it really screams...I love it! There MIGHT be a loss of low end torque...but if there is, it is hardly noticable (perhaps my other mods made up for that). The biggest gain is when at higher speeds. I truly feel it creates a good ram air/cowl induction effect...the car pulls like MAD at 80-85 mph. Rain has been a minor issue...first time it rained the intake had about 3/4 an inch of water in it. That was solved by drilling some holes in the bottom of the box. Since then I have driven in the rain, with no water collection. I do doubt it would be a very good intake to run in the pouring rain though!

Here are the pictures, with a brief explanation under each...


This is a front view (duh!). You can see in the right side of the intake a bolt...we used the stock mounting bracket on the car to hold the intake in.


A side view. The filter is just a cone filter from some perfomance shop, I forget which brand.


The other side. You can see the bolt that goes into the post a little clearer here. I am very proud of that feature...it really gives the box a strong mounting point.


A lower profile front view. Unfortunately the box doesn't sit completely evenly in the car...it was pretty dificult to get a good mold of what it was sitting on. However, I think it I put some thick insulating foam along the lip...it should even it out when the hood closes.


Unfortunately the pictures of the box out of the car didn't turn out well at all...so you really can't see much. But this shows a fairly clear view of the box outside the car. I'll take more if people are interested.

All in all it was a great mod to do. Like I said I haven't really noticed a large loss at low end...which also probably means no gain. Since it is such a large volume of air under the hood, right around the intake, it seems to work as a plenium...just like the stock box does. The volume might be too much though... However...high end is insane...the car just loves it! And hey...that hood scoop? 100% functional now!

Just in case anyone is curious...these are my engine/performance mods
-1st gen Borla header
-custom mid-pipe
-Borla universal exhaust can
-underdrive pulley
-DIY intake

If anyone has any comments, questions, thoughts, etc...let me know! I am happy to answer.

Oh yeah...since I have made this thing...I am going to make at least one more that fits in a little better (especially now that I have fiberglass experience!) I also want to use some aluminum powder in the resin to add to the heat resistant properties. If people are interested, I am sure I could make some for sale. I want to borrow a G-Tech from someone to get some sort of numbers too.

Tell me what you think!

D. Neil Crawford



[This message has been edited by dcrawford (edited January 14, 2001).]
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Old 01-14-2001, 03:02 PM   #2
Penphoe
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sorry man, none of your pics are showing up!

LaterZ!
Darren!!
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Old 01-14-2001, 03:14 PM   #3
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That's really weird. I opened all of those images in a seperate window because they weren't showing up for me, and when I came back they appeared. Odd. Here are the images listed. http://i5.yimg.com/5/24d2df46/h/55d07020/intake01.jpg http://i5.yimg.com/5/24d2df46/h/78722119/intake02.jpg http://i5.yimg.com/5/24d2df46/h/2884f05b/intake03.jpg http://i5.yimg.com/5/24d2df46/h/b26f2774/intake04.jpg http://i5.yimg.com/5/24d2df46/h/a7df5e41/intake05.jpg

Ho-kay. You can't click on those or you'll get an "access forbidden from external host" type message. That's why it's not pulling them up in a message. You need to highlight each line, copy, open a new browser, and paste the addy in the addy/location box.
For some reason his server doesn't like other servers making calls to it's resources.

[This message has been edited by horatio102 (edited January 14, 2001).]

[This message has been edited by horatio102 (edited January 14, 2001).]
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Old 01-14-2001, 03:59 PM   #4
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Lightbulb

I figured it out...I had hosted the pictures in my yahoo briefcase...and yahoo won't let people look at the briefcase pictures unless you are logged on as a yahoo member. So I just posted 'em in my I-Club car pictures. Problem solved!

Now...back to the intake discussion. :P

D. Neil Crawford
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Old 01-14-2001, 04:44 PM   #5
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Thumbs up

Looks good!

LaterZ!
Darren!!
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Old 01-14-2001, 05:24 PM   #6
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it is certainly different......have you noticed any lose in low end torque?

spt
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Old 01-14-2001, 06:03 PM   #7
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Wink

Quote:
There MIGHT be a loss of low end torque...but if there is, it is hardly noticable (perhaps my other mods made up for that). The biggest gain is when at higher speeds
and....

Quote:
All in all it was a great mod to do. Like I said I haven't really noticed a large loss at low end...which also probably means no gain. Since it is such a large volume of air under the hood, right around the intake, it seems to work as a plenium...just like the stock box does. The volume might be too much though... However...high end is insane...the car just loves it
:P :P :P !!!!



D. Neil Crawford

[This message has been edited by dcrawford (edited January 14, 2001).]

[This message has been edited by dcrawford (edited January 14, 2001).]
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Old 01-14-2001, 06:32 PM   #8
Eric SS
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Very nice indeed!

Eric
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Old 01-14-2001, 07:04 PM   #9
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Very Nice...Selling them?....Gerry
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Old 01-14-2001, 07:09 PM   #10
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i assume you use the hoodscoop open does water affect it? it looks good man
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Old 01-14-2001, 07:17 PM   #11
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Exclamation

Quote:
Rain has been a minor issue...first time it rained the intake had about 3/4 an inch of water in it. That was solved by drilling some holes in the bottom of the box. Since then I have driven in the rain, with no water collection. I do doubt it would be a very good intake to run in the pouring rain though!


D. Neil Crawford

PS: If there is enough interest..I would be happy to make and sell them! I need to refine it a bit more first though...and G-Tech it too.
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Old 01-14-2001, 07:22 PM   #12
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Oh yeah...almost forgot.

Thanks for the positive words...it took a long time to make, with a couple really crappy initial errors...but it has turned out very well.

I gotta thank Moe for helping me...and Brucelee and Ravent for the inspiration.

D. Neil Crawford
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Old 01-14-2001, 07:27 PM   #13
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hello,

You know I was thinking about doing the same thing but you guys actually did it!! nice work very inovative. Are you guys gona be selling any of them or gona show us how to do the same thing you guys did? I would really like to have that under my hood till I get my turbo >=). Thanks!

-Randy
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Old 01-14-2001, 09:32 PM   #14
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Will a strut bar still fit?
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Old 01-14-2001, 11:31 PM   #15
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Question

I am not sure if it will work around a front strut tower brace. I imagine it is about the size of some of the larger intercoolers...and some of the tower braces fit around those. I will have to check on that to be sure. I know it will fit under 'em...but I don't know if it will rub against them or anything like that.

As far as selling them goes...I do think that is a good idea. Like I said before I would like to refine it a bit more...make it fit JUST right...and clean up it's appearance a tad bit. And I want to do some water testing (I plan on having a cover panel available for easy installation over the filter...for those rainy days) as well as using a G-Tech (butt-dyno loves it but butt-dyno isn't entirely accurate!).

Since their appears to be some interest...and the post hasn't even been up long...I'll talk to my "business" partner about making a better prototype (which I want to do anyway) and figure out the feasability of a little mass production...as well as cost.

OK! Enough tonight! Gotta work tomorrow. Keep that input and the questions coming!

D. Neil Crawford
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Old 01-15-2001, 12:46 AM   #16
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If you add a peice of fiberglass to cover the top of the filter and allow the air to enter the filter mostly from the side you might be able to prevent problems in the rain. Just a suggestion.
and it looks pretty good.
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Old 01-15-2001, 09:30 AM   #17
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Cool

Brucelee...I was simply standing on the shoulders of giants.

D. Neil Crawford

PS: Mine is WAY better!
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Old 01-15-2001, 10:57 AM   #18
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I'm curious why you feel that you need to worry about whatever heat can be absorbed by the air in this chamber. It doesn't seem like it should be sitting around with any time to pick up any heat, and it isn't being forced through some small diameter hot tube, the volume in that box looks great. I really would like to see what would happen if you put in that rain shield though.

I know on Kawasakis using ram air, there was speculation that as much as 3 psi could be gained at around 100mph.

That was with these tiny little horns that they had in the front of the bike, I wonder what kind of air pressure you are building up in this airbox?

Great job!
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Old 01-15-2001, 10:58 AM   #19
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Actually...the filter does have a velocity stack on the end of it...and having a larger filter on might not make too much of a difference.

I sent you a PM too...

D. Neil Crawford
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Old 01-15-2001, 11:09 AM   #20
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Thumbs up

Thanks Ronin! I used high temperature resin as well as military spec cross woven fiberglass (did a bit of research to find what would be the most heat/chemical resistant) but want to add the aluminum powder to give it that extra bit of insurance against damage from engine heat. So far I have run it in some fairly warm weather..and did not smell any melting resin nor notice any heat damage from the engine. However, I want to make it as strong and last as long as possible. I've considered using carbon fiber instead of fiberglass but it is rather expensive...and the benifits wouldn't be that high (it doesn't need to be all that lighter).

I do believe in the mild supercharging effect though! At high speeds...the car SERIOUSLY pulls...but that is purely my feeling, I haven't had the opportunity to do any sort of real testing.

What I really need to do is get ahold of a stock intake system, a "regular" cone filter aftermarket one (ie. Weapon R, etc.) and a "new generation" (ie. Ganzflow, Cobb...one that retains the stock air box) and do some sort of G-Tech testing with them. I am looking into getting an exhaust temp gauge and A/F meter to see what that tells me too.

So far everything I have made has been psuedo-science...now it is time to get some real numbers.

D. Neil Crawford

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Old 01-15-2001, 04:48 PM   #21
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I'm just gonna bump this one right on up again...and post it in the "General" section too...see what happens...

D. Neil Crawford
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Old 01-15-2001, 06:09 PM   #22
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Looks good. Probably sounds a lot like mine. You probably have a bit more of a ram air type deal going on, but you've got the right idea.
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Old 01-16-2001, 05:12 PM   #23
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Thumbs up

Thanks for all the positive input everyone!

This is what I am going to do...

I am going to make one final prototype for my car...make it as perfect as possible. I'll then make a durable cast of the box so I can run off copies of it.

I'll also find someone with a G-Tech and test out the car, so I can provide some performance numbers to all that are intersted.

At that point...I'll offer 'em for sale! How much you say? Damn...don't know yet!

Anyway...I'll post up more info as it comes up.

D. Neil Crawford
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Old 01-17-2001, 07:55 AM   #24
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Well done. The fiberglass w/o alum. powder will be fine for heat protection, its being cooled by ram air after all....
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