How to: Air filter box modification

[Merlin1]

Fellow cruisers here is a mod I did back in Feb 02 with our first cruiser and I just finished it on the 09 we recently acquired. As you know the inlet on the stock airbox is very small abd restricts airfllow. This mod will open up the inlet to just under 3 inches which will improve performance. This can be done with basic tools found in a well equipped shop or garage. I have a bandsaw but a hacksaw can be used. A dremel tool is helpfull as well as a drill and sanding disc. I did this because I just can't justify the expense of a so called cold air intake setup. This mod is less than $10 and only takes a couple of hours to do. You need a 3" pvc 90 degree elbow that has female and male ends. Here are the steps:
1. cut the female flange off the elbow and then cut the flange to .187 wide
2. remove stock inlet snorkle and open hole to accept the male end of the
elbow
3. glue the small flange on the male end of the elbow on the inside of the box
as shown
4. fabricate (2) mounting clips - 3/4 x 3/4 x 1/2 steel or aluminum - drill 3/16
holes as shown
5. at this point you need to remount the box and correctly position the new
inlet and mark the position because the inlet is slightly off center
6. drill and attach the clips using 10/32 screws and fiber locknuts
7. reinstall the box and check for fit - I had cut about 1/4" off the end of the
inlet to let the airbox mount all the way down on the studs
8. after you have finished the trimming sand the new inlet and prime and paint
I used some high temp black I had which isn't a match but still looks fine
9. Run a small bead of black silicone around the base of the new tube where
it attaches to the box and you are done.
10. Enjoy! Your mileage should improve a little.

[CREWZIN]

Thanks Merlin. Will put that up in the HOW TO section as a sticky.

[wwpptc]

"John's steel blue" won't need one. He's got my old one. I used differant style pipes than you did (still 3") so when i glued the two pieces together they formed a moveable joint as they contacted the shell of the air box on both sides to hold it in place. By doing it this way I could clock the pipe to fit easier in the fenderwell hole as I was putting the box back in place.

Shortly after this install I switched over to the K&N Apollo system.

Jerry

[urimashe]

hello, i introduced myself earlyer on another thread, i have a 2006 base model PT non turbo. i was wondering if this mod is a good mod to use in my airbox with a K&N filter or should i just go with the K&N cold air intake?

[Dino]

Originally Posted by urimashe

hello, i introduced myself earlyer on another thread, i have a 2006 base model PT non turbo. i was wondering if this mod is a good mod to use in my airbox with a K&N filter or should i just go with the K&N cold air intake?

That's up to you, this mod is properly just as good and only 10 bucks and some time. But if your going for a non stock look than go K&N or like I did Airaid.

[soonercruiser]

AirRaid!!

[andreasue]

Originally Posted by urimashe

hello, i introduced myself earlyer on another thread, i have a 2006 base model PT non turbo. i was wondering if this mod is a good mod to use in my airbox with a K&N air filter or should i just go with the K&N cold air intake?

The modification is really up to you. What i know is when i installed it on my cruiser it increased why gas mileage. The air filter model is 33-2960.

[urimashe]

i got the drop in K&N filter, also had them order a tornado for my intake, then ill do this air box modification. when i start the mod I will take some pics.

[Hooligan]

Sorry but the Tornado won't help. Snake oil, waste of money.

[SCBluePT]

Originally Posted by Hooligan

Sorry but the Tornado won't help. Snake oil, waste of money.

Agreed,Tornado is just a gimmick.