DIY Air box mod
#1
Administrator/Jarhead
Thread Starter
DIY Air box mod
Air box mod... Maybe $15 all together. Diesel power magazine said that the 'high performance air intake mods' were really not worth it, the HP and TQ only went up a few # on the dyno, so I did my own based on info from this website.
This may take a few posts.
First, I took the baffles out of the air path. Take the air tube off the air box, all the way down to the turbo. The big fat tube that is smooth houses the baffles. To take this apart, I used a flathead screwdriver to 'pop the top' off. Once I got in, I simply pulled the assembly out. I reassembled the tube using high heat 2-part epoxy. (AutoZone) I recommend getting this before you start the project! (Had to take wife's HEMI to the store.) I left the plastic piece in the bottom in the turbo tube, it was white, and looked like it 'directed' the air into the turbo. (In...Out...???) I went to Lowes and purchased a 4" 90 degree PVC elbow and a coupler for my 'cold air intake'. With my air box completely assembled in the truck, I climbed underneath the truck, worked the PVC in the gap between the turbo and the wheel well, stuck my hand in the pipe, and made a mark with a marker. Then I removed the air box, cut the hole with a jig saw, and put the pipe in WITHOUT SEALING IT to check the fit. I reinstalled the box, climbed under the truck, and put the PVC on/under the air box. Once I had the pipe where I wanted it, I marked the outside of the pipe and the box with the marker, so I would know where to glue it in at. I then removed the assembly, glued the pipe together with PVC cement and used some high heat silicone on the outside. I used a piece of regular screen over the end of the PVC to keep the leaves and other trash out. (Yes, I used duct tape,) Does it add HP? I dunno, but it makes me fell good!!! Remember, this is what I did to my truck, and I am not the biggest brain that you will ever meet. This was on a 04, so it may not apply. I'm going to add pic's of this project tomorrow am, because, apparently, my computer at home sucks, and it takes forever to upload photos.
Feel free to ask ?'s, I'll be happy to respond.
-madhat
This may take a few posts.
First, I took the baffles out of the air path. Take the air tube off the air box, all the way down to the turbo. The big fat tube that is smooth houses the baffles. To take this apart, I used a flathead screwdriver to 'pop the top' off. Once I got in, I simply pulled the assembly out. I reassembled the tube using high heat 2-part epoxy. (AutoZone) I recommend getting this before you start the project! (Had to take wife's HEMI to the store.) I left the plastic piece in the bottom in the turbo tube, it was white, and looked like it 'directed' the air into the turbo. (In...Out...???) I went to Lowes and purchased a 4" 90 degree PVC elbow and a coupler for my 'cold air intake'. With my air box completely assembled in the truck, I climbed underneath the truck, worked the PVC in the gap between the turbo and the wheel well, stuck my hand in the pipe, and made a mark with a marker. Then I removed the air box, cut the hole with a jig saw, and put the pipe in WITHOUT SEALING IT to check the fit. I reinstalled the box, climbed under the truck, and put the PVC on/under the air box. Once I had the pipe where I wanted it, I marked the outside of the pipe and the box with the marker, so I would know where to glue it in at. I then removed the assembly, glued the pipe together with PVC cement and used some high heat silicone on the outside. I used a piece of regular screen over the end of the PVC to keep the leaves and other trash out. (Yes, I used duct tape,) Does it add HP? I dunno, but it makes me fell good!!! Remember, this is what I did to my truck, and I am not the biggest brain that you will ever meet. This was on a 04, so it may not apply. I'm going to add pic's of this project tomorrow am, because, apparently, my computer at home sucks, and it takes forever to upload photos.
Feel free to ask ?'s, I'll be happy to respond.
-madhat
#2
sounds good dude!
So basically you routed a tube from the airbox to underneath the truck to capture the 'cold-air'?
If so, I thought about doing this, just havent had the time. I have about six 1.25" holes in the bottom of my airbox, but I want to get some colder air in there so I think i'm going to make one of the center holes bigger and do what you described with either some rubber tubing or pvc.
Did you get a faster spool up by any chance?
So basically you routed a tube from the airbox to underneath the truck to capture the 'cold-air'?
If so, I thought about doing this, just havent had the time. I have about six 1.25" holes in the bottom of my airbox, but I want to get some colder air in there so I think i'm going to make one of the center holes bigger and do what you described with either some rubber tubing or pvc.
Did you get a faster spool up by any chance?
#3
Just a plain ole guy
I've been thinking about adding a BHAF, but all I've seen are setup to draw hot air from under the hood. The idea of making a clean, slick cold air pickup and smothing out the air path has me thinking of ways to accomplish this.
#4
Registered User
Madhat,
That's exactly how I modded my airbox. With the airbox mod, 5.5" aluminum tubing for the silencer tube replacement and the silencer ring removed my turbo will sing.
Great mod for less than $20.
MikeyB
That's exactly how I modded my airbox. With the airbox mod, 5.5" aluminum tubing for the silencer tube replacement and the silencer ring removed my turbo will sing.
Great mod for less than $20.
MikeyB
#5
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Join Date: Mar 2006
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Here's my airbox upgrade with Home Depot parts.
http://www.cascade4x4s.com/pics/2006...rbox/index.htm
http://www.cascade4x4s.com/pics/2006...rbox/index.htm
#6
Registered User
Here's my airbox upgrade with Home Depot parts.
http://www.cascade4x4s.com/pics/2006...rbox/index.htm
http://www.cascade4x4s.com/pics/2006...rbox/index.htm
I like the storm drain cover idea. Do you remember the OD of the drain cover flange?
MikeyB
#7
Check out Good hoods ram air setup for the 3rd gens. Nice looking srt type hood and it is plummed over to give "ram air" Looks more like a nice cold air provider. The hood is like 500. So if you not into stylish looks than yours is perfect. But if you truck is a Big Boy toy then I would recomend the hood. It's on my list. I more mod (Banks pda) then the hood
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#9
Administrator/Jarhead
Thread Starter
sounds good dude!
So basically you routed a tube from the airbox to underneath the truck to capture the 'cold-air'?
If so, I thought about doing this, just havent had the time. I have about six 1.25" holes in the bottom of my airbox, but I want to get some colder air in there so I think i'm going to make one of the center holes bigger and do what you described with either some rubber tubing or pvc.
Did you get a faster spool up by any chance?
So basically you routed a tube from the airbox to underneath the truck to capture the 'cold-air'?
If so, I thought about doing this, just havent had the time. I have about six 1.25" holes in the bottom of my airbox, but I want to get some colder air in there so I think i'm going to make one of the center holes bigger and do what you described with either some rubber tubing or pvc.
Did you get a faster spool up by any chance?
#10
Administrator/Jarhead
Thread Starter
Here's my airbox upgrade with Home Depot parts.
http://www.cascade4x4s.com/pics/2006...rbox/index.htm
http://www.cascade4x4s.com/pics/2006...rbox/index.htm
#11
Just a plain ole guy
Is your tube just a dryer vent hose? Any chance it will get sucked flat? I've heard of mods opening a hole in the bottom of the box, but that will be subject to dirt water from the tire area. I really like this idea shown.
#12
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Join Date: Jul 2005
Location: Bryan/ College Station, Texas
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I would also put some window screen to catch the grass > leaves > bugs > and small cars that get suck into the hole or it will be a fun time getting the expensive filter cleaned out... I know... I did this on my old PSD and I had things in the air box you wouldn't believe... I pulled a bird out once! And lovebug season>>> you think getting them off you truck is fun... wait till you clean out your filter... the smell will make you want a Chuck bucket near by... AND then there is Junebug season.. and Grasshopper season...
I would rather clean a screen than the groves in the airfilter.
Oilguy