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How to: Air filter box modification

 
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  #1 (permalink)  
Old 07 Oct 2010, 09:42 am
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Join Date: Sep 2010
Location: Tulsa Oklahoma
Posts: 115
Default How to: Air filter box modification

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.
Attached Images
File Type: jpg Stock inlet (1).JPG (95.1 KB, 1699 views)
File Type: jpg Open inlet (2).jpg (25.9 KB, 1621 views)
File Type: jpg Cut off female flange (3).JPG (73.6 KB, 1535 views)
File Type: jpg Cut flange to .187 (4).JPG (81.6 KB, 1329 views)
File Type: jpg Glue flange (5).JPG (76.6 KB, 1339 views)
File Type: jpg Top angle clip (6).JPG (84.2 KB, 1339 views)
File Type: jpg Bottom angle clip (7).JPG (79.7 KB, 1289 views)
File Type: jpg Paint (8).jpg (31.7 KB, 1374 views)
File Type: jpg Reinstall (9).JPG (82.2 KB, 1364 views)
File Type: jpg Still looks stock (10).jpg (30.4 KB, 1565 views)

Last edited by CREWZIN; 07 Oct 2010 at 10:06 am.
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Old 07 Oct 2010, 10:06 am
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Join Date: Sep 2001
Posts: 27,743
Default Re: Air filter box modification

Thanks Merlin. Will put that up in the HOW TO section as a sticky.
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Old 07 Oct 2010, 02:31 pm
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Join Date: Sep 2009
Location: south of Tampa, Florida
Posts: 3,037
Default Re: How to: Air filter box modification

"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
Attached Images
File Type: jpg 053 hood at rest.jpg (69.0 KB, 857 views)
File Type: jpg 132.0 NA air filter box.jpg (34.8 KB, 928 views)
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Old 17 Nov 2010, 03:12 am
urimashe's Avatar
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Join Date: Nov 2010
Location: anchorage alaska
Posts: 289
Default Re: How to: Air filter box modification

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?
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Old 17 Nov 2010, 11:12 am
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Join Date: Feb 2010
Location: NY
Posts: 1,839
Default Re: How to: Air filter box modification

Quote:
Originally Posted by urimashe View Post
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.
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Old 17 Nov 2010, 10:17 pm
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Location: Oklahoma City
Posts: 7,257
Thumbs up Re: How to: Air filter box modification

AirRaid!!


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Last edited by soonercruiser; 17 Nov 2010 at 10:21 pm.
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Old 18 Nov 2010, 08:23 pm
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Join Date: Nov 2010
Posts: 4
Default Re: How to: Air filter box modification

Quote:
Originally Posted by urimashe View Post
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.
Ptin13ss likes this.

Last edited by andreasue; 19 Nov 2010 at 08:05 pm.
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Old 20 Nov 2010, 04:01 am
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Join Date: Nov 2010
Location: anchorage alaska
Posts: 289
Default Re: How to: Air filter box modification

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.
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Old 20 Nov 2010, 10:54 am
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Default Re: How to: Air filter box modification

Sorry but the Tornado won't help. Snake oil, waste of money.
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Old 20 Nov 2010, 11:50 am
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Default Re: How to: Air filter box modification

Quote:
Originally Posted by Hooligan View Post
Sorry but the Tornado won't help. Snake oil, waste of money.
Agreed,Tornado is just a gimmick.
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