jlibert

After reviewing the ****** whistler thread, I decided to use some of the resources (intakehoses.com) and ideas to build an intake like the whistler (thanks 53 ******!!!) At some point I'll build a heat shield, and may possibly put on an outerwear for the winter. After a weeks worth of driving (1000mi or so) I see no reason to worry about the proximity to the exhaust manifold. As far as performance goes, turbo bark seems much less violent, more whistle than the AFE intake, and the Amsoil filter is very easy to clean.
For the construction of the intake, I used the filter from the ****** whistler thread (I think it's a 6080). I used a 5 to 4" reducing elbow, a 6" to 5" reducing elbow, 1' of 6" tubing and 1' of 5" tubing. It was my first time trying to weld aluminum, but it came out ok. It's a very tight fit near the oil filter housing, but after trimming back the 5" to 4" reducing elbow at the 4" side, it fit nicely. Again, all credit to the ****** Whistler thread. This is basically a ****** Whistler with different reducing elbows to try and maximize airflow. This costs more than the 53 *****'s method and uses 5" intermediate tubing vs 5.5" in an effort to smooth the airflow into the turbo.

Here is the parts list:
1. (1) 5" to 4" 90* reducing elbow
http://intakehoses.com/Merchant2/mer...ory_Code=R9DEN
2. (1) 6" to 5" 90* reducing elbow
http://intakehoses.com/Merchant2/mer...ory_Code=R9DEN
3. 1 foot of 6" aluminum tubing
http://intakehoses.com/Merchant2/mer...gory_Code=SIT7
4. 1 foot of 5" aluminum tubing
http://intakehoses.com/Merchant2/mer...gory_Code=SIT7
5. (1) 4" T Bolt Clamp
http://intakehoses.com/Merchant2/mer...gory_Code=TBC5
6. (2) 5" T Bolt Clamps
http://intakehoses.com/Merchant2/mer...gory_Code=TBC5
7. (2) 6" T Bolt Clamps
http://intakehoses.com/Merchant2/mer...gory_Code=TBC5
8. Amsoil EaAU6080 filter
http://www.amsoil.com/StoreFront/eaau.aspx

**NOTE**

-you probably only need 6" of the 5" tubing
-the amsoil filter comes with a 6" worm style clamp
-you can re use the factory 4" clamp at the turbo

53 willys

Nice Job...good first welds too.
you actually made the intake smaller then mine...mine goes 6" to 5.5" to 4" turbo flange...unless I am missing something??
either way you did a great job and saved some cash too

53 willys

what did you use to trim the rubber elbow by the turbo??

jlibert

maybe it is smaller than yours. I used a razor blade.

53 willys

You did a nice job and yours does not use the stock turbo elbow either..witch is a bonus IMHO

jlibert

I chose to go from 4 to 5 to 6" mainly because of the smooth transition of the 4 to 5". It gradually steps up to 5" instead of flaring out to 5" at the end of the elbow. I would have never attempted this without your thread. I would have spent $400+ on an AFE and been just like everybody else.

wap

So have you had an AFE on the truck before?

I might have to make one of these if it is louder than an AFE.

jlibert

It's not a whole lot louder than the afe, but its a different pitch. Sounds more like a jet, less like the wind howling. With the afe, the turbo would bark violently between shifts. With this intake, the bark is minimized greatly. Don't really understand why, anyone care to explain?

53 willys

Only thing that I can think of is the Amsoil filter may flow better???
Disclaimer....this is not fact, just a guess

TX_Diesel

So Jilibert,

do you have a parts list to share with us??

jlibert

Post at top of page has been edited to include this information

1. (1) 5" to 4" 90* reducing elbow
http://intakehoses.com/Merchant2/mer...ory_Code=R9DEN
2. (1) 6" to 5" 90* reducing elbow
http://intakehoses.com/Merchant2/mer...ory_Code=R9DEN
3. 1 foot of 6" aluminum tubing
http://intakehoses.com/Merchant2/mer...gory_Code=SIT7
4. 1 foot of 5" aluminum tubing
http://intakehoses.com/Merchant2/mer...gory_Code=SIT7
5. (1) 4" T Bolt Clamp
http://intakehoses.com/Merchant2/mer...gory_Code=TBC5
6. (2) 5" T Bolt Clamps
http://intakehoses.com/Merchant2/mer...gory_Code=TBC5
7. (2) 6" T Bolt Clamps
http://intakehoses.com/Merchant2/mer...gory_Code=TBC5
8. Amsoil EaAU6080 filter
http://www.amsoil.com/StoreFront/eaau.aspx

**NOTE**

-you probably only need 6" of the 5" tubing
-the amsoil filter comes with a 6" worm style clamp
-you can re use the factory 4" clamp at the turbo

TX_Diesel

thanks bud. So are we gonna call this version the Jlibert whistler. LOL

wap

Mark, just thinkin out loud but if the stock intake doesnt bark but an after market one does wouldnt that mean the better/easier the air flows through the filter, the easier it you can bark the turbo?

If this theory is true then wouldnt the amsoil filter not flow quite as well as the AFE?

Disclaimer, again, just thinkin outloud.

jlibert

I was kind of confused on this deal too. Basically the bark with the AFE was very pronounced; Big whoosh sound. Now it sounds more like a wastegate opening on a sandrail (for lack of a better explanation. Guys that go to Glamis know what I'm talking about) I would guess that there is less of a restriction, OR*** there is more volume inside the new intake therefore absorbing much of the pressure coming back through the turbo ???

53 willys

I don't know?? my stock intake on my 01 (auto)barked EASY...I don't think I have ever barked the new trucks turbo (06manual)...with stock intake or the whistler....So basically I have no clue as to why that would be...they seem to bark with the stock intakes too
I really need to call Amsoil and get some specs from them.....
maybe some smarty pants will enlighten us cause I would like to know...