another BA airbox in AU question to end them all

[S3SR]

ok so i tried that mod a long time ago but never tried cutting the box to bits to make it fit perfectly...today i took it out and took pictures.

now can anyone whos done this 'cutting' please tell me where to cut....the redish stain on the box is where its rubbed against my engine bay paint.....im guessing that where i cut but any help please tell me..

oh and how did you patch the hole?...is that plastic able to be heated and remolded or is it thermosetting plastic.

i have almost every angle of the box if you need more.

hopefully this should also help anyone wanting to do this later on, or abit worried about it fitting.



EDIT: looking now i dont think the ruler will help at all, the box is on an angle oh well treat it as coordinates

[AU2PWR]

Originally Posted by FALCONSR

ok so i tried that mod a long time ago but never tried cutting the box to bits to make it fit perfectly...today i took it out and took pictures.

now can anyone whos done this 'cutting' please tell me where to cut....the redish stain on the box is where its rubbed against my engine bay paint.....im guessing that where i cut but any help please tell me..

oh and how did you patch the hole?...is that plastic able to be heated and remolded or is it thermosetting plastic.

i have almost every angle of the box if you need more.

hopefully this should also help anyone wanting to do this later on, or abit worried about it fitting.

It Will NOT Fit without cutting it a Fair Bit ,About 5cms from the Flat Bit your showing towards the top of the Airbox on the Bottom Half Should be Enough ..

[S3SR]

Originally Posted by AU2PWR

It Will NOT Fit without cutting it a Fair Bit ,About 5cms from the Flat Bit your showing towards the top of the Airbox on the Bottom Half Should be Enough ..

did you patch the hole or leave as is?....mine fits just not the top 2 bolts im lazy and scared ill stuff it up....its not broken so i wont touch it

[AUXRVIII]

Get the hair dryer out, heat the areas where the red paint is and use a piece of timber to reshape it.

[GK]

Originally Posted by AUXRVIII

Get the hair dryer out, heat the areas where the red paint is and use a piece of timber to reshape it.

That's a good idea I reckon. If it doesn't work, then you can cut it!

GK

[S3SR]

Originally Posted by AUXRVIII

Get the hair dryer out, heat the areas where the red paint is and use a piece of timber to reshape it.

was thinking oxy but yes ill try the hair dryer first

though i dont know whether that plastic will just get hot and eventually burn or heat and become soft enough to remold.....it is in an engine bay remember

[AU2PWR]

its thermoset , wont budge with heat ..

[AUXRVIII]

Originally Posted by AU2PWR

its thermoset , wont budge with heat ..

It works for AU airboxes, so I figured it will for BA. I've found if you get any plastic hot enough it can be reshaped. If a hairdryer doesn't get it hot enough a heat gun certainly will.
The plastic needs to be much hotter than the heat an engine bay radiates thats why it's not affected.

[AU2PWR]

heating something thermosetted will de-strengthen it . becomes brittle , learnt this working for a Plastics Moulder .. The Heat needs to be concentrated in a Small Area , Heat Gun or Hair dryer is too big

[AUXRVIII]

Yep I can accept that, but reworking the bottom of an airbox by heating it isn,t going to adversly affect anything or result in failure of the box.

[AU2PWR]

Cool , so when the Engine Bay heats to its usuall 80 degree ambient temp and your stress heated airboxs cracks when its Cooled and Heated about 5 times , you can come back and say .. Bugger i Should of listend to the Fat Red Haired Kid ...

[RG]

Daniel is right, it will crack and I'd say you'll be lucky to even get 5 cycles of heat and cool out of it. Just remember too it may only be the bottom that cracks but it is more than likely that the lid will come free and then you'll have unfiltered air entering your engine.

[AUXRVIII]

I made the suggestion becuase I have heated the parts of the airbox where the spring type clips are fitted for LPG, the top is always in place after backfire, clips also remain in place after backfire, when Tickford used to fit the LPG systems they did a similar thing, if the mod can survive a backfire then I can't see a problem with this.

[AU2PWR]

Totally Different Situation , the backfire is 3% Heat , 95% Pressure and 2% LPG , Hence the Air Not Escaping the Intake Quick , pressurising and blowing the top off the Airbox ,..

Heating it will cause it to loose its strength and then crumble later on , so when the car Does Backfire on the good old BBQ Gas , bits of Airbox go into the Throttle Body and .. Well you know the rest ..

Now here is something i could help with

When i had a stab at this before just cutting mine , the BA/BF Lid Just Missed fittin on teh AU Bottom , try and fix this Riddle .. and you will have one better than me .. But Heating it is a no no ..

Cheers
Daniel

[AUXRVIII]

I think you need to have another read of my post. I heated the airbox where the clips are fitted. This acording to you weakens the airbox. Now if the box can survive backfires, how is an unstressed part of a lower box going to fail?

[JC]

Just get a BA XR8 pod and be done with it. Apart from a small piece of adapter silicon hose (2.5" to 3" joiner will work), it fits like a bought/made one. Ever wondered why the BA XRs didn't come with the square box, and why BA owners upgrade to the Pod filter setup (and the Pod owners upgrade to G&D). Just save all those hops, skips & jumps and buy a G&D/Bluepower box, or the value alternative, the XR8 Pod (it's all you need for the I6).

[StealthAu]

Originally Posted by JC

Just get a BA XR8 pod and be done with it. Apart from a small piece of adapter silicon hose (2.5" to 3" joiner will work), it fits like a bought/made one. Ever wondered why the BA XRs didn't come with the square box, and why BA owners upgrade to the Pod filter setup (and the Pod owners upgrade to G&D). Just save all those hops, skips & jumps and buy a G&D/Bluepower box, or the value alternative, the XR8 Pod (it's all you need for the I6).

where do you get these from (I'm guessing ford) and how much are they?

[chief]

Here is a link to the FTG pod filter kit they sell.

http://fordforums.com.au/showthread.php?t=46888

[FGII-XR6]

i have moded my AU box with an extra 3" pipe at the front i plastic welded it and it looks and performs well I just used a short PVC fitting from bunnings cut to suit I then used black vinyl spray to make it look the part

[Brisbane ghia]

looks sweet, did you notice performance gains

[FGII-XR6]

with the other mods yes and sounds better too also got KN filter Tickford snorkel and Hyclone(don't cringe I tested and on petrol it gives 60 to 80 Ks extra on a tank not as much on lpg but stiil there are gains) advance extractors 2.5" redback system now I love driving through maccas drive through the echo is awesome.

[RG]

Originally Posted by AUXRVIII

I think you need to have another read of my post. I heated the airbox where the clips are fitted. This acording to you weakens the airbox. Now if the box can survive backfires, how is an unstressed part of a lower box going to fail?

It's not unstressed as heat causes stress, and there is plenty of that in your engine bay.

Originally Posted by au3xr6

i have moded my AU box with an extra 3" pipe at the front i plastic welded it and it looks and performs well I just used a short PVC fitting from bunnings cut to suit I then used black vinyl spray to make it look the part

Real bad idea, PVC pipe cracks after a couple of weeks. I and many others on here have tried it and we have all had the same result, cracked PVC pipe.

[JC]

Originally Posted by stockoau

where do you get these from (I'm guessing ford) and how much are they?

I got mine through AFF - they come every now and then for around $100, but the wreckers, trading post etc. One guy in Canberra got one for $50 - I thought my 2 for $200 with BMC high flow filter and standard filter was good (which it was).

[AUXRVIII]

Originally Posted by RedXR347

It's not unstressed as heat causes stress, and there is plenty of that in your engine bay.

Like I said, I have modded them with a heat gun on lpg engines and no failures have occured to the modded area even after a backfire, how can you dispute that?
Only last Friday I serviced an 279000km EF with factory lpg which had the airbox spring clips secured by heating the box still had all of the clips in place. The rest of the intake tubing had plenty of tape covering splits and breakages.

[private9]

Originally Posted by stockoau

where do you get these from (I'm guessing ford) and how much are they?

I bought mine for $150 and came with a new paper element, K & N element, pod box, bracket, lower front snorkel and the pod box has also been modified by SVO to accept an XR6T snorkel, plus it came with the XR6T snorkel. Was rapt!

[JC]

Originally Posted by private9

I bought mine for $150 and came with a new paper element, K & N element, pod box, bracket, lower front snorkel and the pod box has also been modified by SVO to accept an XR6T snorkel, plus it came with the XR6T snorkel. Was rapt!

Similar deal to mine, but I got an extra box as well, which meant I did both cars.

Talking of BA bits in other cars, I just re-engineered and fitted a fully functioning BA shifter handle (auto) into my EL. I've seen others, but they don't actually work when you press the button - this one does! sleep:

[S3SR]

Originally Posted by JC

Similar deal to mine, but I got an extra box as well, which meant I did both cars.

Talking of BA bits in other cars, I just re-engineered and fitted a fully functioning BA shifter handle (auto) into my EL. I've seen others, but they don't actually work when you press the button - this one does! sleep:

pics or ban

[JC]

Originally Posted by FALCONSR

pics or ban

Already had a "holiday" once, so it's no big deal having another one, but here are some pics anyway:

More work done during the night while watching the Aussies cream the Sri Lankans. Anyone notice my approx 5 hour mod here?


Yes, it's a BA shifter adapted to fit the E series "stalk", and the mechanism inside reversed so that pushing the button activates by pressing on the stalk (the BA one normally pulls up the stalk), meaning all the detentes work, so you need to press the button to P-R, R-N, D-N, R-P & N-R & 2-1. One of the most small, challenging and yet rewarding mods I've ever done, because I had to engineer around an @r5e-about mechanism (thanks to Rollin for the inspiration, sort of).

[JC]

Originally Posted by FALCONSR

pics or ban

And before you ask - It could possibly be adapted to fit an AU.

[S3SR]

Originally Posted by JC

And before you ask - It could possibly be adapted to fit an AU.

lol i wasnt going to.....i got manual

i just wanted to see this one as it was talked about so much doing it in the AU

love your work, NOW adapt the aston martin "flappy paddle" style gearbox for my AU..lol apparently better with a auto box anyways