Custom intake

[aurmend]

I'm going to make a cheaper knock-off of Hennessy's and bpd1151's intake. i will make a write-up as i go. I just need to wait for the air filter to come in to measure the inlets and i also need to measure the turbo inlet as well. i will be using am inter-cooler kit off of ebay and use couplers to join the pipes. (i haven't decided whether to expand the pipes and put one inside the other then couple it together and weld it down the line. Also black inter-cooler pipes or normal polished aluminum pipes)

I will be posting future updates here so if you guys have any comments or suggestions post them here.
Also if you guys know the measurement of the stock turbo inlet that would be great.


Update 1: The Air filter 30 MAR. 2017

S&B KF-1014.
It has Dual 3" inlets and a single 3/4" inlet for an IAT sensor.
If you need to plug it a 1" ID (25mm) vacuum plug fits perfectly. I need to buy a Vernier Caliper to accurately measure the IAT inlet.

These are approximate measurements

TOTAL LENGTH: 9 5/8" LENGTH WITHOUT INLET: 9" INLET LENGTH: 5/8"
Front side measurements:
WIDTH: 8 1/2" HEIGHT: 4 34"
Back side measurements:
WIDTH: 5 7/8" HEIGHT: 3 7/8"

I just bought a 3" intercooler pipe kit for $85 arriving soon.

For the vacuum lines I used the 10mm OD from vibrant. It's 6.4mm ID http://vibrantperformance.com/catal..._1147&osCsid=08e5ee45c4819ec3c2a532b0b8ce8429

It looks like I need a 15mm drill bit to install the grommet. I bought 3 for $22

Done!

Ignore the vape sounds and sorry i can only go 0-40mph because im on a military post






REQUIRED PARTS:

S&B Filters KF-1014 $55
OBX 2895 aluminum VACUUM LINE FITTING 10MM O.D $21
16MM Drill bit or step drill bit for Vacuum fitting $15max
UNIVERSAL 8PC 3" ALUMINUM INTERCOOLER PIPING $85
25mm 0.99" Silicone Blanking Cap for VTA Mod and IAT $7
10 x Hose Clamps Worm Clips 3/4"-1 $7
2" to 3" 90 Degree Silicone Reducer Elbow Black $11
1.75" T Bolt Clamp For the front turbo $4
Piping Reducer 2" OD to 3" OD $12
IF RUNNING Stock PCV
5/8" Fuel line hose 1 foot $5
5/8" to 3/8" hose adapter $5
3/8" fuel line hose 1 foot $5
TOTAL $232
OPTIONAL
Dorman Help! 02602 Expand Tite for noisemaker delete $6
3" **** hoses $7


i used a hacksaw to cut the piping.
and a deburring tool

How to make it (all you need to do is cut and drill 3 holses)

Rear turbo < Piping Reducer 2" OD to 3" OD <3" coupler < 3" 90 degree intercooler pipe<3" coupler < 3" 45 degree intercooler pipe < 3" coupler < 3" 90 degree intercooler pipe <filter

Front turbo < 2" to 3" 90 Degree Silicone Reducer Elbow Black < 3" 90 degree intercooler pipe <filter

 

[xFallenxCripplex]

I would go black pipe with red couples or just black

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[aurmend]

Alright, black on black it is. I still have to figure out how im going to connect the PCV hose And that Vacuum line without welding. I will be doing all of this in my barracks room and in the parking lot. If i have to weld one piece I might as well get every thing welded

 

[xFallenxCripplex]

Jb weld? If so I've gotten best results by making a liquid epoxy and the puddy sandwich to hold alot of tension in my projector headlight mod on my 01 Impreza since I had steel laying around and the projector housing is aluminum.

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[xFallenxCripplex]

I'm sure there are better ways but don't know exactly where you need it could just drill a hole and on one side of the piece going thru have a buyer side so it won't get pulled thru and use a clamp on the other.

Or screw this in
https://m.summitracing.com/parts/ea...0cUJ-jxBn09LhG5e2EzFXkTa9d6tZZoi34aAgDM8P8HAQ

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[BamSHO]

Need to join the Ecoboost Enthusiasts on Facebook. There are couple guys who did there own too, they could help you out, if you need some advice or get stuck.

 

[aurmend]

Thanks for the heads up

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[BamSHO]

Welcome!

 

[aurmend]

So, I have not measured the turbo inlets but I have an unconfirmed measurement of 1.5" OD.

If that is the case what is the downside of using a 3" to 1.5" reducer like this one.
https://www.amazon.com/dp/B00N34G0TK/ref=cm_sw_r_cp_apa_UI.4ybT2E7VY4

(No silicone reducers available)
Is it better to go from 1.5" to 2.25" then 2.25" to 3" (reducer elbow)?

EDIT: Good news, i measured it and it came out to me 46-48mm

What should i do with the PCV hose. found oil on turbo entrance and inside the pipe?

 

[aurmend]

http://www.ebay.com/itm/Clear-Air-O...ash=item1c78f21595:g:p4gAAOSwZQRYXcbL&vxp=mtr

Thoughts for this PCV system for the front? it has 3/8" barbed fitting with 1/4" NPT threads
It can withstand 150PSI
i might as well be the first one to test it out and if it works ill use it on both sides

Edit: i just realized its a ******* overpriced compressed air filter with the inlet and outlet switched
I'm going to try it though

 

[aurmend]

Little update




Unfortunately I do need a 2" to 3" metal pipe for the rear Turbo or a 2" aluminum "joiner" pipe

 

[FearlessAZ]

Looks good! Can't wait to see final results.

 

[gimpy]

Nice work sir, looking good.

I'm sure if you made a few 'extra' a good amount of members would be happy to exchange that folding green stuff for them.

 

[aurmend]

Yeah, unfortunately these are hand made and not perfect. I'm using a hacksaw, maybe I can use a band saw or something. I just need to dial down the measurements and stuff. When I'm finished I should have a revised items needed.

If I were to sell them I would use 6061 aluminum with fitting you can screw in and have them powder coated and shipped. If I has access to my dad's tools it would be no problem but unfortunately I'm very far away and living in an apartment.

 

[gimpy]

stuff you can read above

Interesting...and interested

I'll be sure to follow this

 

[aurmend]

I have no idea how I'm going to start the air box though. Might use aluminum sheet then but some heat tape or something.
Or the ghetto way of buying a rubberish mini trash can and cutting out the appropriate area and somehow making the stock air guide into it

I might just outsource it to my dad and he can make a solid titanium intake lol

 

[aurmend]

ALL COMPLETE!!! except for the air box.

Check the first post.
The intake sound is considerably louder

Will update later with required parts.

 

[gimpy]

Excellent.

This guy, right here... he gets shit done.

 

[aurmend]

I added pricing for the parts.
I paid a lot more than $232 since i had no idea (kinda) what i was doing
I calculated it and i paid $402 for everything. And still no airbox, ill make it before the month ends hopefully


Next up: 2" hot pipes????

 

[aurmend]

Also, any recommendations for gauge pods? What to buy so I can mount them? I want to wire up a meth kit and a flow gauge before I get a tune to run it

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