I saw a few posts on this and people saying they'd like to do it, so I took some pictures of my project. Unfortunately, i don't have pics of the original cardboard box I made to get the template to cut the aluminum, but here are the rest of the steps I took, along with some pics:

1.) I built a box of of a cardboard 12-pack. Cut out thte bottom and secured it with tape, and then built the rest in one-wall sections to make sure I worked with small pieces.
2.) Taped all of the cardboard together and trimmed a little more to make sure it all worked at the same time. (hint: when you need to make a strange angle, it helps to cut a piece of spare cardboard to that angle so you don't lose the angle when the cardboard moves).
3.) Cut the Aluminum Flashing (you might want to use something heavier, but I wanted easy to work with material, so I chose flashing). This part was pretty straight forward.
4.) Test fit the Aluminum before putting together
5.) Assemble the box however you feel is right.
6.) After assembly, cut holes for intake hose and AFM (I didn't do this yet since mine is still being finished as we speak).
That's it!

I used flashing, so I needed to insulate and paint it. I used rubberized undercoating to insulate it (3 coats), then used black paint to seal it and give it an even more flat black look. Here are the pics of it in a few stages. The last one was taken about 15 minutes ago and I still need to get the holes cut in it. Feel free to offer suggestions.

box cut and laid together, not secured
http://www.geocities.com/njrhea/Box-Alum.jpg
taped and riveted together
http://www.geocities.com/njrhea/Box-Tape.jpg
Painted with Undercoating and one coat of black paint
http://www.geocities.com/njrhea/Box-Black.jpg

 

Links no workie.

Glad to see people thinking outside of the box vs. buying a manufactured product. Good Luck! I'm sure it looks good.

 

buying a box (manufactured one by company) is really dumb and a waste of money. If someone made a home business out of it and made em cheap, then that wouldnt be a rip off

edit: what im saying is, dont go out and buy a 150 air box when if someone makes you one for like 30 bux in their garage

 

just click the link, then put a space in front of it... Geocities licks nuts, so you've gotta find ways to make it work. Here's a couple more too.

You can see the general fit (I'm going to patch the hole by the fender wall with some foam or something)
http://www.geocities.com/njrhea/Box-Front.jpg
You can see the fit against the intake side and the mounting bracket (I believe it's a heatsink for the fuel system ,but could be wrong)
http://www.geocities.com/njrhea/Box-Side.jpg
The TID I made about a week ago that made me need this box
http://www.geocities.com/njrhea/TID.jpg

 

 

??? What's that for? Link not working?

in any case, I just cut an opening for the stock intake tubing to come into the box. I think I'm going to cut a hole and make "fingers" come out to hold my TID, then plumb the AFM in through the inside of the box. If anyone has suggestions for upgrades or anything they'd do different, let me know, cause I might be making another one in a little while.

 

I think that box looks awesome and it gets me motivated to go do my own. I just finished with the TB mod so now I'm looking for other free/cheap mods to do and this one looks like a good idea. A quick question though....I want to get rid of the stock plastic "scoop". I see that you left yours and I've seen other people leave their's also.....will the box not get enough air if the scoop is removed?

 

You'd have to come up with another way to get air into the box. My idea was this... I'm leaving the fan shroud, so why not keep the "snorkel"? Also, I think i'm going to expand a little down the road and run a PVC pipe with a collector type box to the front end of the car. Depends on how creative you are. I'm not, so I left it.
Just in case anyone's interested. I got it finished up and have a couple pics of the "finished" product. I still need to put another coat of undercoat and paint on it and then drop it in. Hopefully that will get some more air in, and now when people search (IF they search, that is...) they'll turn this up and might get some ideas of how I did it.

http://www.geocities.com/njrhea/Box-Filter.jpg
http://www.geocities.com/njrhea/Box-Back.jpg

 

Hey Man could you post a list of parts you used to make that TID? It looks phat. Thanks

 

yeah I'll try to remember here....

2" rubber coupling
2 x 45° street elbow (a 90° might've workedout)
2" to 3" rubber coupling

I needed to cut the one 45° angle for my last set-up, then i just used to cut piece for this one. You might be able to make it a little cleaner if you use different angles. I've also heard people say they like the 3" the whole way back, but I would've had to find mandrel bent exhaust piping, and I didn't have time, so I'm going to look into upgrading mine to that in the near future. Good luck with yours if you decide to try it

 

want cold air?
do what i did, cut a hole in your body, take the window sprayer bottle out and use some pvc pipe to put a filter down there, bypass all your coolant lines, now that is some cold air

 

Does anyone have the pics from this project? PM me or Email them to me if you have them. I want to make this myself. Thanks djaaronp@yahoo.com

Aaron