smm12

Hey guys, this weekend I was working on making a "cold air intake" for my s4 TII and thought I would share with you how I did it. This project was intended to use the stock intake piping for the time being until I make room to do something more elaborate (FMIC). This meant that I had to manipulate it a little to make the new air box fit which lead to needing a new tube to make the stock BOV fit with the stock intercooler setup. Also I don't think that this would ever work if you still had the air pump as the intake piping ended up sitting where that used to be.

Parts needed:
AFM adapter, sheet metal and rivets/nuts and bolts, filter (still need a real one), tubing for stock BOV
Comes to a total of around 30 bucks plus the filter

I started off by getting the AFM and intake piping into the position that I wanted and then proceeded to make cardboard templates to build the heat shielding/air box. I waited till the end to worry about the BOV as mentioned and ended up moving a few of the resistors that are bolted around and under the stock air box to make a little more room The process of making the shielding took a lot longer than I had thought it would but I wanted to try to make it look as factory made as possible. While making the template I made sure to use the same mounting bolt locations as the stock air box did just to keep it simple. The picture shows what the template looked like once it was done, all that was left was to trace it and bend it up. To bend the metal I just used a vice and some square tubing that was laying around because the vice wasn't large enough for the bends.






After doing the vertical part of the shield I decided to make a floor for the box as well same thing as before more cardboard templates until I was satisfied with the way it looked.



After getting the shielding for the air filter done I realized that I still had to make some room because the filter that I was using to mock every thing up was just hitting the heat shield for the resistors behind the headlamps so I ended up moving them around inside of the air box so that I didn't have to do any wiring. Maybe later on I will try to clean that mess up.




After getting everything done for the shielding and air filter I finally had to make a pipe
for the BOV. I found some hard plastic 1/2" tubing that was laying around the basement and just heated it up and bent it so that I could fit it.



It ended up looking a bit messy but this part will hopefully only be temporary. I will probably end up doing some ducting to get more air from outside of the car to the air box later as well. If I where to redo this I would have made sure to fold tabs along the top edge of the box it seemed a little bit flimsy. I still have to grab some weather stripping for the edges around the hood and the inner fender; that should help to hid some of my bad cuts along that inner fender at the same time. Was happy that it started right up after this with no real problems especially because it hadn't been run for over two months. Let me know what you guys think, not really expecting much of a performance gain this was mainly a starter project for the winter to get me going onthe list of other things that need to be done before spring.

misterstyx69

iTrader: (142)

Good job and a Nice contribution to the Section.
Thank you. STYX (MOD)

Evil Aviator

Add to the 2Gen archive?

Maybe replace this old thread that no longer has pictures?
https://www.rx7club.com/2nd-gen-arch...ive-me-305195/

smm12

Thanks guys, figured I should finish this up now that its 99% complete, never added ducting tho ran out of time. I did get a turbo xs bov so I wouldn't have all of the crappy pluming involved with trying to use the stock BOV. That bov worked out really well for me didn't have to do any welding or buy a specific install kit. All I did was cut the nipple off, just the raised part on the end, of the intercooler pipe that hooked up the stock bov and made it a press fit with the aluminum adapter included with the bov.

Happy with it so far still want to get a aftermarket/custom pipe from the filter to the turbo but just ran out of time, blew a connecting rod on my old winter beater had to put it back on the road earlier than planned. Put almost 2,000 miles on it since i got it back on the road and everything has been holding up good including the radiator, FPR, battery relocate, and fuel pump rewire that I did this winter. Still lots of work to do just to much snow still to feel like doing it.

smm12

DE.FD

Pretty solid walk around the project. Looks great!

smm12

I was thinking about turning this into a build thread but that would probably end up being a 5+ year long thread haha

itr78

that is pretty clever. i enjoy reading the custom creative mods especially since aftermarket parts for these cars are not as abundant like on other cars, and you get to save some $$ with these custom kits..

smm12

Thanks again for the good replies, if you guys saw the outside of this car you would be wondering why i spent so much time on it. But anyway for anyone reading this looking to put a bov just because it sounds cool, same reason I did its, and less ugly pluming, (so much fun!! and you get some good flames), the only thing I would have done different is add some silicone or something just in case it leaks. It is a press fit so once you do it that is it you can't mess with it.

On a side note has anyone figured out the 3800 hesitation? I have tried grounding the boost sensor, rewired the fuel pump with a Areomotive 360? pump, have a FPR, on the stock intercooler, running 10 lbs of boost, also I have 720 Secondaries with a rtelk 1.7. After everything I still lean out to 14's, which is better than 16's/17's before the fpr and fuel pump rewire but still not happy. It is nice getting the extra power for the split second but not worth a motor, 14's to lean even for the split second, especially for what I have heard about predet on these motors. Any suggestions would be great; hope to track this car for the first time, me and it, at BIR, after the power cruise in july.