DIY intake cover thing.

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DIY intake cover thing.

Postby VanillaIce220 » Thu Feb 09, 2017 11:31 am

Hey all.
Recently I have "upgraded" to a front mount for more efame, but beside that point I am going to try and make my own box for the cold air intake to reduce the heat. What would be the best and easier material to work with? I have been reading a little and I think aluminium sheet would be the best? I would like a second, third and fourth opinion.
Just with sheet metal I can bend and play around. Plus I can always get someone to weld it together or bolt it together.
Whats everyones thoughts?
Thanks.
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Re: DIY intake cover thing.

Postby VanillaIce220 » Thu Feb 09, 2017 11:41 am

what about stainless?
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Re: DIY intake cover thing.

Postby VanillaIce220 » Fri Feb 10, 2017 1:08 pm

I like talking to myself, but for those who are reading... I went with stainless. From what I gathered aluminium is a great heat conductor, but easy to work with, like bending and cutting. Stainless is much worse at heat conduction (which is what i want) but it harder to work with. Ideally tungsten is the perfect material to avoid heat.... but it is near impossible to buy tungsten sheets, not to mention the price would be insane... plus finding someone to weld... not sure how i would go about that.

So pretty much what I will be doing is... copying the cobb air box, however to fit my pod I will need to extend certain parts. My intercooler piping will be running through this box and this happens to be the hot side of the intercooler piping. So with the air box I will probably make my own vent for the back to allow air to come in and exit. I am not a scientist, however I though that if the hot side is in the air box towards the back, it will disperse heat. So if I have an exit (vent) at the back, it will allow atmosphere air to coming in through the stock intake thing, be sucked up by my cai and also vent out the back where the hot side of the intercooler pipe is which in my mind, the cai will no suck the hot air generated by the intercooler pipe.... Now I might be wrong.... I probably am but that is just my thought process ahah.
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Re: DIY intake cover thing.

Postby VanillaIce220 » Tue Feb 14, 2017 2:24 pm

So basically I cut up cardboard and put it in place. The back is a mirror image of the cobb air box the rest is of my own making. I would cut out a large amount and if i cut to much, I would stick it back on with duct tape. I did this for most of Sunday in 43 degree heat. It was very fun. Monday I took it to some local blokes to cut and fold for me. I simply do not have the tool required for cutting and folding stainless neatly. I would place the box in the engine bay to check, some modification was needed. I then tacked on 3 stainless nuts to the box. at the bottom... not very neat but you don't see it. I am pretty good at judging how much to cut and what to cut off. The top was annoying... ended up stabbing myself with the sharp corners. I had to re drill holes which blunted my piece. I have to grind off a section to feel the carbonfibre intake shroud thing, that stuffed the grinding stone because I am new to it and because the grinder grinder I have shat itself. I became a pro at pulling it off and putting it back together.
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Re: DIY intake cover thing.

Postby VanillaIce220 » Tue Feb 14, 2017 2:24 pm

and I placed the pictures the wrong way so go down to up ahaha.
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Re: DIY intake cover thing.

Postby Lushtaco » Thu Apr 20, 2017 8:39 pm

good work!
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Re: DIY intake cover thing.

Postby VanillaIce220 » Fri Apr 21, 2017 6:52 pm

Many efames, Many wows. However, it has recently gone under construction. The Front mount piping was hitting the top when I backed off. So now there is more room there and a little neater.
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Re: DIY intake cover thing.

Postby bigBADbenny » Fri Apr 21, 2017 8:21 pm

However the boxes work out, ensure its shielding intake air from the heat of the adjacent headers down below ;)
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Re: DIY intake cover thing.

Postby flux » Wed Jun 21, 2017 12:10 pm

If anyone wants to make their own, and uses Autodesk Inventor 2016, I can send you my parts and assembly files using the rough dimensions from Kane that I am using for my own box (sans intercooler piping cuts). As I haven't measured where my intake piping will go, I have put in a mock up 85mm piping hole but you can edit the files however you please to better fit your own set up. Also, I haven't transfered these to cardboard to test fitmet yet, so will update when I do. Here are some pics, just pm me for the files.

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Also note, I have not even measured lid dimensions yet, just went by Kane's pictures so it could be way too wide/wrong shape still. I will get around to test fitting it with cardboard and finalising measurements and fitting sizes after my last exam on the 01/07/17
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Re: DIY intake cover thing.

Postby VanillaIce220 » Thu Jun 22, 2017 10:49 pm

Mate that some awesome work there. Its pretty close to mine. The top of the box will need some fiddling around the sides closest to the fender. I will take mine off tomorrow and try and get a picture of that. I have also created a larger hole for the intercooler piping as it was hitting the top of the box. I will take a photo of that too. Might not be able to post for a while. The top of my box is just one flat plate. However, that slight bend looks better, kind of looks like a little home haha.
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Re: DIY intake cover thing.

Postby flux » Thu Jun 22, 2017 11:27 pm

VanillaIce220 wrote:Mate that some awesome work there. Its pretty close to mine. The top of the box will need some fiddling around the sides closest to the fender. I will take mine off tomorrow and try and get a picture of that. I have also created a larger hole for the intercooler piping as it was hitting the top of the box. I will take a photo of that too. Might not be able to post for a while. The top of my box is just one flat plate. However, that slight bend looks better, kind of looks like a little home haha.


Haha thanks. Yeah any help is appreciated.
I smashed my exam today so I went in to uni afterwards and printed off the design over 2xA3 sheets and will transfer to cardboard and test fit tomorrow (bit of a reward to myself for doing well).

I'll keep you posted. :)

Also, up side is I can just export final design as a PDF and people can just print it off over 2xA3 sheets of paper and do it themselves if they wish.
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Re: DIY intake cover thing.

Postby flux » Fri Jun 23, 2017 5:30 pm

Test fitted today.

Mostly fits really well, have updated my files with the changes.

- Shaved a bit off the sides as it was too wide and would cause excessive rubbing
- Lid had to be scaled in a bit as well to accomodate (noticebly thinner by headlight/snorkel at front)
- The feet were a bit off, I drew them too elongated, they need to be long and thin not short and fat - reverted to more your original style.
- Added a few smooth curves here and there.
- Added another tab for a support on the back panel.

Apart from that I'm pretty happy with how it will look. Will finalise the rest when my piping arrives so I can figure out where the pipe is going to go through and AFM is gonna sit, etc.
Not sure how you managed to fit a screw in by the headlight/snorkel entrance, my tab barely sticks out enough to fit a nut and bolt. Considering just making it a solid support leaving it as is.

Still a bit to be done, here's what it looks like now.

Image
Image
Image
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