Another New Intake Assembly

jimt3te50 · 18-11-2007, 03:02 AM

Hey everyone,

I know, I know- another airbox, so called "CAI" thread!

Maybe a little bit different though. Given my commitment to making this thing even better, I have been stuffing around with several types of intake to get something that really works well in the T3. Now with a little bit of tickling, it needed something a bit better than what I had, so after waiting and waiting for an airbox to be developed I had a go at one myself.

Using a bit of the experience drawn from the LS1 guys, I decided that if i was going to stay with a pod, I wanted it to effectively be a heat shield first and foremost and then do the job it needed to do better than what I had. At this point I don't know if it is better (no dyno or track times) but it would have to be as the filter doesn't get anywhere near as hot as it did running exposed like it has been since day dot.

The filter is a huge K&N with 90mm MAF and 4" stainless intake, 2 x 45deg rubber elbows and hose clamps. In a moment of pure genius, I made the "box" using a lid from an old barbecue cover (that looked new btw), using a TED beer carton, aluminium foil, wire and masonite as templates in various stages. All up I guess it's taken up most of the week working on it after the wife went to bed.

Have to say I'm both proud of and wrapped with the results- see what you reckon.....

poolkeeper · 18-11-2007, 09:40 AM

Looks like G&D airbox, nice work

Can you still close the bonnet with that battery, seems like its sitting very high lol

xr8ute · 18-11-2007, 10:26 AM

Nice work, that looks great

JoesAu · 18-11-2007, 10:29 AM

that looks pretty sweet hey! you gonna put a lid on it??

EF Futura 07 · 18-11-2007, 10:36 AM

looks good, well done! how does she sound???

:

jimt3te50 · 18-11-2007, 10:56 AM

Thanks guys- sounds great actually- it's been an open pod for about 18 months now so in a way I would say it's probably a bit quieter.

The bonnet closes fine with the battery and the airbox and the box seals on the bonnet when closed and this is the way I wanted to do it- alot of the LS1 systems do this and they all rave about it, I haven't seen such a Ford system so thought I'd give it a go. The hardest part was getting the contours right, particulay where the seal on the top of the box meets with the trim on the underside of the bonnet, but thats where the aluminium foil came in ;) - as did it for the contours of the inner guard, which I transferred to a beer carton, which was transferred to a masonite template, which I modified and made the final touches to get a 'hard' template. Once it fitted I laid the stencil on the metal, used a can of spraypaint to mark out the shape and then cut it out of the enamel coated steel. Once it was all cut, just folded it using a piece of wood, tidied up the edges with a dremel grinding wheel, pop riveted on two 90degree brackets to bolt it in the car. cleaned up the white marker and spray paint with some turps, ran a bead of silastic around the bottom of it and done!