I just finished my install for my BHAF setup. I've posted pictures in my gallery if anyone is interested, but the two final installed pictures are pending approval. I have three pictures of the pieces before installation for a better idea of what I did.

I made an attempt at making a shield to protect from most of the spray from the bottom and the front. It turned out OK but not as ambitous as I originally wanted to do as I was hoping to make a more complete box. Original plan called for the 90 deg. steel elbow to be part of the box but I evetually decided to allow the filter to just rest on the shield allowing for it move freely so it can move with the engine. It went through some cutting and rework so don't be eyballing my welds as I'm just learning and I wasn't taking the time to make a show piece. I did shoot some silver paint on all the metal parts for protection.

This thing just barely clears the hood with the way I have it, and I had to cut a relief in the bottom of the shield just to get that. The back of the BHAF actually touches the alternator. I will be adding an outerwear cover at some point anyway for further protection since water/spray could still get to it somewhat.

Haven't road tested it yet, just started it up and let it run. Reved it up to 2500 rpm or so and didn't notice any more noise than usual. Seemed to run a bit smoother than normal, but more likely just my wishful thinking.

I keep records on my mileage so I'll post back after I have a run a few tanks through to see if that changes.

 

looks good. good fab skills for the IAT mount.

 

Gosh darn it Berak.... I don't have enough time as it is... and there ya go giving me more excellent ideas for my truck. I'm very impressed at the console setup. What'd you use to in fabbing that??? Also, what's the part number for that bhaf....it looks a bit smaller than others???
Thanks again.... T.

 

Can you post the measurements for your IAT mount?? What size are the holes? spacing, etc...Thanx

 

Nice setup. Do you think the shield is necessary if you're using an Outerwears cover?

 

04ctd: Thanks.

trik396: There is some more info on my website here. Basically the sides are MDF and I made a subframe from angle iron. The inside has a rack mount system similar to computer racks. The BHAF is the standard NAPA 2970 everyone is using.

Herrin821: I didn't really take any measurements as I built the IAT mount, I just used the sensor itself as the template. Made the top first, drilled the center hole, used the sensor to locate the holding screws, etc.

Hoss: Thanks, I think the shield will keep out 90% of any water but I think the outerwears is still a good idea because moisture could still get to it if I hit a really big puddle. Also, one thing I haven't seen anyone mention is what happens when you have to pop the hood when it's raining? Just a little extra insurance.

 

Oh, and just to add one more thing. The shield is made from 16 gauge sheet metal excepting for the bracket which 1/8" flat stock (1.5" wide I think). The elbows and clamps were bought from airflowonline and I used 4" exhaust tubing which is thick, not their aluminum intake tubing.

The tools I used for everything are just the basic stuff, nothing fancy. A jigsaw, bench vise (my cheap sheet metal brake), drill, and an inexpensive MIG welder.

 

I intended to update this thread with any MPG changes but any comparison now is going to be problem as I started using my Espar heater pretty often after getting the filter done. I've added an outerwears cover to the filter.

Many have stated the noise was worse with this setup but all I can tell is a barely perceptible high pitched turbo whine under hard acceleration and nothing much different at all when cruising. Of course my aggressive tires are probably masking any intake noise increase.

 

nice looking setup there...

 

How much to buy, looks good.

 

Thanks guys. 03', if you want to build one you can get all the parts I used at airflowonline (although they may be running out of the 4" exhaust tubing I used). Otherwise it's just some 16 gauge sheet metal from the local tractor supply store. If you have even basic welding ability it really wasnt that much work.