The kd4crs/Power Hungry/Gotts Mod (revisited - and with pictures)

***Power Hungry*** · #1 Tue, January 27th, 2009, 11:53 AM

Now all we need to do is talk Jack into making about 2 dozen of those pipes and we'll start selling them as the "J&J Snorkel Kit" so nobody has to make their own.

Jack, is there a reason you couldn't use the original flex bellows? That would save a couple bucks not having to by the 3" coupler hose.

***Jackpine*** · #2 Tue, January 27th, 2009, 02:50 PM

Quote:

Originally Posted by Power Hungry

Now all we need to do is talk Jack into making about 2 dozen of those pipes and we'll start selling them as the "J&J Snorkel Kit" so nobody has to make their own.

Jack, is there a reason you couldn't use the original flex bellows? That would save a couple bucks not having to by the 3" coupler hose.

As a matter of fact -

One of the things about me is that I'm rarely satisfied with a first attempt.

This morning I discovered that the 3" ABS pipe actually fits rather snugly inside the bellows of the original intake. So, I pulled my intake out of the truck again and reinstalled the bellows on the end of the tube running into the air cleaner box. Then, I slipped my new snorkel into the bellows and reinstalled it back into the truck.

Now the new intake looks like this:

The bellows is a little more flexible, and the intake fits into the fender wall better now. I used a hose clamp (tightened snugly, but not really too tight) to provide more stability, but I'm not even sure that it's needed. I didn't even bother to cut the pipe shorter, so the only change is the bellows instead of the coupler.

Making this change allowed me to wipe off the fender wall so it doesn't look so hideous. (But I could have done a better job

- jbrew, if you see this, don't barf).

So, the total cost can be reduced to one hose clamp and one length of ABS tubing. (Anyone want to buy a slightly used coupler with one missing hose clamp)?

No, I'm not going into the tube making business! That part took about 3 hours of careful sanding, fitting, resanding, etc.

- Jack

***Power Hungry*** · #3 Tue, January 27th, 2009, 03:32 PM

Looks nice with the bellows on there. Give the aesthetics of it, I'd doubt the dealer would even spot it except for the rubber grommet missing.

I do have one question (or favor) to ask... When you have time, could you pull the tube out and trace a pattern of the sanded end on a sheet of paper and scan it or fax it over? We'd like to be able to post it on the forums so folks can have a reasonable template to go by if they should decide to try and do it themselves.

For what it's worth, we might even be able to see if we can get them molded. I've got a guy that does carbon fiber molding that might be able to make them relatively inexpensively.

Once again, great job.

***Jackpine*** · #4 Tue, January 27th, 2009, 03:49 PM

Quote:

Originally Posted by Power Hungry

Looks nice with the bellows on there. Give the aesthetics of it, I'd doubt the dealer would even spot it except for the rubber grommet missing.

I do have one question (or favor) to ask... When you have time, could you pull the tube out and trace a pattern of the sanded end on a sheet of paper and scan it or fax it over? We'd like to be able to post it on the forums so folks can have a reasonable template to go by if they should decide to try and do it themselves.

For what it's worth, we might even be able to see if we can get them molded. I've got a guy that does carbon fiber molding that might be able to make them relatively inexpensively.

Once again, great job.

I think the carbon fiber molded idea is a great one! I'll be happy to pull, trace and fax the cross-section, but it probably would not fit into the fender wall hole without grinding off the small "lip" in the opening as I did. I measured the original oval in the fender at 3 1/8 x 3 1/2, using a pair of dividers, since I don't have any inside calipers. By grinding the opening, I was able to make the short diameter about 3 1/4". I was worried that sanding down the tube to 3 1/8 across would make it too weak.

What we really need is a tracing of the inside of the fender hole (unmodified). But, I don't see how one could get anything behind it to trace on.

- Jack

AgentOrange · #5 Tue, January 27th, 2009, 05:09 PM

Hi guys & gals, brand new to this forum. I stumbled across it while checking out other homemade CAIs after tinkering with one of my own and this was the first one I've seen that had an excellent one for the 2004 +. I like the caron fiber idea.
Here is a pic of what I came up with (hopefully the pic works):

***Jackpine*** · #6 Tue, January 27th, 2009, 09:11 PM

The pic came out just fine AgentOrange (and welcome to the forum).

That's a pretty "sexy" looking intake. Sure doesn't look "homemade" (or cheap either).

Where'd it come from? And, what does it cost, does it work, etc., etc.?

- Jack

AgentOrange · #7 Tue, January 27th, 2009, 10:39 PM

Quote:

Where'd it come from? And, what does it cost, does it work, etc., etc.?

- Jack

Thanks...It's actually the stock tube with the baffles cut off and capped. I also sealed the 6 holes you mentioned with silicone sealant. I took the bellows end off and replaced it with a flexible 3" Y pipe then I ran some 3" flexible metal ducting into the fenderwell and another length of ducting through the radiator support down to the rear of the tow hook which should add a little bit of ram air effect. I like your use of the ABS plastic pipe into the fenderwell better, however, so I might steal that idea later...BTW, do you think the end that is inserted into the fender could be heated and formed to fit inside the oval opening to avoid the sanding?
As far as it making a difference...to early to tell. I am still using the stock filter, which I plan to change to a Amsoil soon, so I doubt I have seen the full potential. I have not heard any whistling noises as of yet, but I haven't done any interstate driving or made any high RPM runs yet...I'll follow-up if I notice any strange sounds. I'll follow-up on MPG's also. Since the mod, which has only been a couple of days, I haven't driven my normal route which is very short with a lot of stopping and starting, so any numbers I would give now would be misleading.
Total cost was around $30 for the parts.
I have several other pics of the mod in my album...check 'em out.
Originally, I was going to do the same mod as you sans ABS pipe, but then I saw the Y-pipe while I was shopping for the other parts and figured hmmm...2 cold air inlets would be better than 1, so that's what I came up with.

92 5.0 · #8 Fri, February 13th, 2009, 03:37 PM

where to buy and what size caps/plugs did you need to cap off where the baffles were? Is it louder now with the baffles removed?

Quote:

Originally Posted by AgentOrange

Hi guys & gals, brand new to this forum. I stumbled across it while checking out other homemade CAIs after tinkering with one of my own and this was the first one I've seen that had an excellent one for the 2004 +. I like the caron fiber idea.
Here is a pic of what I came up with (hopefully the pic works):

AgentOrange · #9 Fri, February 13th, 2009, 10:50 PM

Got them from Lowes. I'll try to get the sizes for you tomorrow. I have not noticed a difference in sound, but I'm still using the stock air filter. There might be a difference with a K&N replacement filter...but not sure.

schwinn1weld · #10 Tue, August 25th, 2009, 11:16 AM

Quote:

Originally Posted by AgentOrange

Hi guys & gals, brand new to this forum. I stumbled across it while checking out other homemade CAIs after tinkering with one of my own and this was the first one I've seen that had an excellent one for the 2004 +. I like the caron fiber idea.
Here is a pic of what I came up with (hopefully the pic works):

Looks Great, but what did you use to cap the holes on your main intake tube? Looks awesome how you did that...