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View Full Version : CAI finished on my TJ2 AWD



EZ Boy
16-11-2004, 10:24 AM
Here 'tis. 90mm PVC, heat reflective tape, PVC glue, hack saw and a heat gun.

Just need to put some shrouding around the pod and I'll be set. Will post some comments on fuel economy, performance etc in a week or so.

WhiteDevil
16-11-2004, 10:41 AM
That's nice work. I quite like that, I may copy it if you haven't patented the idea already. hehe.

TRboy
16-11-2004, 11:03 AM
that looks realy neat, did you notice any difference with it?

nice colour car 2!

Phonic
16-11-2004, 12:00 PM
Real nice, notice any difference, in piticular a willingness to rev out quicker? :D

Black Beard
16-11-2004, 03:49 PM
Nice use of PVA bends. did you manage to fit that diameter all the way down past your transmission?? looks like you did - must be a tight fit. How'd you get it to 'fit' into the air box??

KX_69
16-11-2004, 03:58 PM
wheres your AWD engine cover?

GVR4WA
16-11-2004, 04:02 PM
Probably took it off like the most of us who don't care for gimmicks.

TheDifference
16-11-2004, 06:41 PM
you need to fully enclose the pod other wise the CAI is as useless as a one legged man in an @rse kicking contest.

Mulga
16-11-2004, 07:05 PM
Nice work, love the use of the original airbox without relocating the MAF. :cool:

One thing though, are you planning on putting mesh infront of that inlet?

Imagine a stone kicked up by a car in front of you getting into that system. :shock:

Let alone a cat or small child getting sucked in!!


Sorry, didn't see the POD.

MadMik
16-11-2004, 07:44 PM
It looks nice bro but unless you enclose the pod it will get little to no fresh air at all. If or once it is enclosed then it will create the vacuum needed to suck the air thru. I used to have my TF setup the same way and it got bugger all fresh air. I've since relocated to just behind the NSF bumper and she runs way better!! :bowrofl:

turbo_charade
16-11-2004, 07:52 PM
what are the intake temps compared to before?

Killer
17-11-2004, 09:03 AM
Using heat resistant tape is good idea - perhaps not the best looking, but... cool.
Definitely cover the air filter - otherwise the whole idea of CAI (Cold Air I) is defeated.
Yeah, use squirrel catcher at the front - we have too many missing kids in Ozland already!

Iron Man
17-11-2004, 09:10 AM
Don't Magna's/Veradas already have a cold air intake? :nuts: The big plasticky chute leading from the airbox forward to the radiator support, drawing air from in front of all the hot stuff like engines and radiators??

cthulhu
17-11-2004, 09:23 AM
Don't Magna's/Veradas already have a cold air intake? :nuts: The big plasticky chute leading from the airbox forward to the radiator support, drawing air from in front of all the hot stuff like engines and radiators??

Yes they do, but it's a tiny as hell chute and it sucks from between the bonnet and the top of the front bar which is an even smaller hole.

GVR4WA
17-11-2004, 09:38 AM
I don't understand what his tried to do with that POD all the way in the enginebay still sucking from its usual position in peoples cars?

It looks like a normal POD mounted to MAS sensor, then a RAM scoop coming from stock panel air filter? Why the hell is that first POD uncovered?

EZ Boy
17-11-2004, 04:42 PM
Whoa there!

Ladies and Gentlemen,

I didn't say that I'd cured cancer, merely installed CAI piping for my AWD.

I'll address the Q's in the order they appeared unless repeated.


WhiteDevil: Thanks. Go nuts man! Just be brave with the hacksaw!!

TRboy: Thanks again. Would you believe it hasn't left the garage since it's 5minute commissioning drive Sunday. I think the mrs is on to me

Phonic: I'll tell you later in the week.

Black Beard: I used 90mm all through. I could have left it round past the radiator hose but it carries a lot of heat so I used a heat gun to cave in the pvc pipe at the required locations. I then used heat resistance rubber(?) from off my water heater in the laundry to protect it from rubbing. It would have been an impossible fit if I hadn't cut the whole side out of the battery box.

KX_69: Somewhere in the shed, keeps too much heat around the engine imo. Same as the tortoise shell on the ecotec V6's which I owned in a past life...

TheDifference: I know, but if it didn't all come together I didn't want to fuss about putting the pod back on etc. Plus I LOVE the sound of it roaring the air in!!! I notice too that RPW show the pod behind the original air scoop and front half of the 'box on their website. I asked Dave if that was the craic and he said "that's how it goes". Fair enough. The real benefits will be when the vehicle's at speed when cooler air is rushing around the pod and *hopefully* getting drawn in. Most hot air is sucked under the car the hotrod boys tell me. For people that don't usually drive with a bonnet on their car I thought it would require some additional quantifying.

Mulga: Thought about mesh but with the rear half of my air box not connected, I hope that critters, water, stones, telemarketers etc will not get too deep into my pod. Lets face it, the existing stock air scoop and box just gathers this sh*t, bakes it and gives it up for us when we remember to open the bloody thing.

MadMik: I really wanted to relocate the POD and MAS to the front bumper but I've been talking to some Drifter (they wish) tryhards who tell me that have nothing but dramas with water, dirt, bugs, etc burrying the pod filter. If anyone has a solution I'm all ears.

turbo_charade: Sorry, got no idea honestly.

Killer: see above.

Genocide: Um, look again. Scoop below bumper, feeds into front of airbox, pod and mas. Again RPW reckons this is sweet, I'm trying to figure out how to shroud it. In a perfect would I was better off with the panel k&n - but I just LOVE that pod roaring!!

Thanks again for the interest, I hope someone learnt something or mustered a little more courage to have a go themselves. :thumbsup:

GVR4WA
17-11-2004, 04:45 PM
Ok, sure mate, hope your happy with the setups outcome.

TheDifference
17-11-2004, 04:48 PM
oh, ok. RPW does it, and they say its good....... then it must be great.......... :doubt: :nuts:

EZ Boy
17-11-2004, 05:18 PM
Didn't waste any time hey? :upyours:

Read carefully: "I'm trying to figure out how to shroud it."

If you already know everything then why are you on the forums? In fact, why did you buy a Magna? Maybe you're like me and couldn't get lease finance on a '99 Audi A4 quattro.

cthulhu
17-11-2004, 06:16 PM
Nice work mate. I hope to do something similar soon but every time I go to the hardware store they're out of Round Tuits.

The one thing that concerns me is the abruptness of your 'scoop' and how the intake pipe basically seems to be at right angles to the oncoming air. Have you considered adding even a 45deg rotation to the contraption on the intake end of the pipe?

sherriff
17-11-2004, 07:51 PM
if you wantd you could make a clear perspex cover to create a seal around the pod and the airbox?

Datto
17-11-2004, 08:09 PM
EZ Boy: A few years back we played around building a bunch of different CAIs for a mates 626 V6 (pretty similar engine bay layout). In the original seup our pipe (off cuts from an exhaust shop, cheap cheap) followed pretty much the same path, but we had the unifilter pod mounted low, pointing at the ground. It was a pretty effective setup, performance was tops, but as you said there were problems with dirt and water. If you do build such a setup it would be wise to build some kind of water trap (a low point) into the piping....might just save your engine. The other problem was that he had to clean the filer every two weeks.

The final setup involved relocating the battery to the boot (again, same postion in the engine bay), and mounting the pod in the front corner. The pod was boxed in, and a cold air feed run up to the box from under the front bumper. Works a charm.

One additional note, having an open filter (ie not in some form of airbox) is not legal and you can be defected for it.

TheDifference
17-11-2004, 08:16 PM
One additional note, having an open filter (ie not in some form of airbox) is not legal and you can be defected for it.

only if its an oiled filter. ie K&N

Tim-E
17-11-2004, 08:35 PM
Nice work mate. I hope to do something similar soon but every time I go to the hardware store they're out of Round Tuits.

The one thing that concerns me is the abruptness of your 'scoop' and how the intake pipe basically seems to be at right angles to the oncoming air. Have you considered adding even a 45deg rotation to the contraption on the intake end of the pipe?

this is why i used 45 degree and 22 degree elbows throughout my setup. I only used 90 degree one just when it comes out of the airbox. Good work though EZ Boy, ignore the doubters who are probably too lazy to do something similar.

Using a panel would have been much less hassle for you, but if u like the roar then fair enough. personally i think i would get very sick of that roar, so it went with a panel.

Uni holidays have finally arrived for me, so i will be doing a bit more work on my CAI, may even make another with 100mm

Datto
17-11-2004, 08:52 PM
only if its an oiled filter. ie K&N

Ahh k. Hadn't heard that before.

WhiteDevil
17-11-2004, 09:09 PM
do you guys have a very big butterflies??? What's the point on going so big, are you hoping for more than 100% efficiency of your inlet piping??? if it flows then really all you need is something slightly bigger than your butterfly, anything more than that you're just overkilling it, if you're doing it for the looks, fine... but don't expect a few mm difference will gain extra ponnies.

i think you should stick a ducted fan in there too while you're at it, check out the great range of R/C plane motors, then you won't need ramming effect, you create it! PS, don't use your battery, just get the rechargable batteries that comes with the R/C motor. HAHA...

Datto
17-11-2004, 09:33 PM
do you guys have a very big butterflies??? What's the point on going so big, are you hoping for more than 100% efficiency of your inlet piping??? if it flows then really all you need is something slightly bigger than your butterfly, anything more than that you're just overkilling it, if you're doing it for the looks, fine... but don't expect a few mm difference will gain extra ponnies.

Not quite. Think of the total pressure drop in the inlet piping as being the sum of the pressure drop at all the points along piping. If you can reduce the restriction at one particular part of the piping you'll reduce overall pressure drop. Having piping bigger than the throttle body would definitely be a good thing. Eg, 3" pipe into a 2.5" throttle body will flow better than 2.5" pipe into a 2.5" throttle body.

WhiteDevil
18-11-2004, 08:34 AM
Not quite. Think of the total pressure drop in the inlet piping as being the sum of the pressure drop at all the points along piping. If you can reduce the restriction at one particular part of the piping you'll reduce overall pressure drop. Having piping bigger than the throttle body would definitely be a good thing. Eg, 3" pipe into a 2.5" throttle body will flow better than 2.5" pipe into a 2.5" throttle body.

that's exactly what I meant, 3" is 76.2mm, the throttle body is 65.0mm.
So what's the point in going to 100mm???

While you're talking about pressure drop, there's a huge pressure drop at the entrance of the Air Box, so what are you going to do about that?

Mr İharisma
18-11-2004, 08:50 AM
Is black flexy piping good for the CAI instead of PVC? Seen a couple of race cars use it from under the front bumper to a pod sitting in a CA box ( basically like our standard box but modified, then running to the turbo ( RX-7, 300ZX etc ).

cthulhu
18-11-2004, 08:54 AM
Doesn't really matter what kind of piping you use so long as it has a smooth surface. Any corrugations or ridges on the inside surface will be bad for airflow.

Datto
18-11-2004, 09:17 AM
Whitedevil: Don't use it at all. :)

Mr İharisma: Fine if it's big diameter.

cthulhu: You can get away with using the ribbed stuff, you just have to go a larger diameter. All depends on whether you have room for it.

EZ Boy
18-11-2004, 11:45 AM
The one thing that concerns me is the abruptness of your 'scoop' and how the intake pipe basically seems to be at right angles to the oncoming air. Have you considered adding even a 45deg rotation to the contraption on the intake end of the pipe?

This factor was very difficult: I couldn't fit additional pipe bends in, and I couldn't remove the pipe to heat it again and make a bend. :cry:

The pipe actually lays back at 12-14degrees, not much but better than the original scoop I hope!

I think I've done okay so far. I've only spent about $45 all up. The insulation tape was the real thief. I scored the pipe from offcuts at a building site, the plumbers couldn't give me enuf of the stuff :)