Roush CAI Mods on 2011

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Festus Hagen

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Ok, I bought my 2011 SHO almost two weeks ago. I noticed when looking at the car that it had a Roush CAI, normally that would be a bit of a turn-off but the car felt so "tight" and ran so well, I figured "ok, saves me the trouble" and bought the car anyways.

I read up on other CAIs (primarily the Airaid) and found that drivers had concerns with the intakes pulling from the engine compartment, and also having heat transfer through the intake box. Found some mods that others have done, none of what I'm posting was "my idea" but this is what I did on this cold day in NY.

Here's how it looked when I started.
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No idea why the molding stops where it does <shrugs> Let's pull the filter and molding.
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Kinda gross in there. Ok, I cleaned the inside thoroughly. Earlier in the day I picked up a roll of this stuff at Home Depot. Was looking for Reflectix, but had an idea that this stuff, being self-adhesive, might be easier to work with.
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I got to work measuring and cutting pieces to line the inside of the box. I reasoned that I should leave that oval-shaped part in the bottom alone, it looks like it wants to act as a drain. I normally would go by "neatness counts" but my fingers were freezing and I planned to tape all of the edges with aluminum tape, which I did. An insulator's "smoothing tool" is handy for this work if you happen to have one.

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I had also picked up a stick of foam pipe insulation (I think I chose 1/2" pipe size, no particular reason). I started by positioning this on the right hand side where it's tight, working it around, and when it was all in place, removed the plastic tape from the adhesive on the pipe insulation. Here's the finished works.

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I'm not 100% sold on the pipe insulation, will give it a whirl for now and chalk it when I get a chance to see how it's sealing with the hood (or not sealing). Might try to find an alternative. I'm really more of a laid-back kind of driver (not racing anybody) but if the engine gets cooler air through the intake and gains efficiency from that, it's all good! It's not rocket surgery, but hit me up with any questions.
 

SHOdded

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Nice work for a freezing day :) Should work pretty well, look forward to your impressions. We have a few folks who have done this mod with just the replacement of the rubber strip along the molding, with good success. But insulating the entire box is even better. bamsho has added more airflow with additional ducting to the front bumper area.
 

bpd1151

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Boy, even now I am growing suspicious.....

That CAI design (not your foil / weatherstripping mods) sure looks eerily familiar to not only Airaid. But also to LMS/LME & now "Roush"?

Boy I tell 'ya, the original fabricator of that mold is sit'n pretty somewhere having sold off that design to God knows who.

Good for them I suppose.

To the OP..... You taught me a new term as it relates to a piece of equipment....

An insulator's "smoothing tool".

Very cool! :thumb:

The results of your efforts, even in the cold outdoor temps, speak for themselves. Well done.
 

Festus Hagen

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Thanks! Agree on the similarity of design, after looking at the car the first time I was google-searching for the intake from memory, and was sure it was the Airaid product.

Re: Smoothing tool- There may be another or more correct name for the thing, I asked an HVAC insulator what they are called and that's what he told me. I guess a picture is worth a thousand words, this particular example I liberated from the top of an insulated duct where I found it in the field. I guess the worker left it behind, oops! Not much to it but it just "works", the ridges in the middle give you a good grip and the size, flexibility, and rounded edges allow you to iron-down the tape without tearing it very often. I'm not even sure where you'd buy one, I think they come along with cases of tape sold to the HVAC industry.

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bpd1151

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Ha! Those "tools" are referred to simply as squeegees in the sign/vinyl industry.

Been using the exact same device for many years now myself.

Ironic that a different trade/industry is using them in a different capacity.

Hmmm. Learn something new everyday.
 

Festus Hagen

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Ha! Those "tools" are referred to simply as squeegees in the sign/vinyl industry.

Been using the exact same device for many years now myself.

Ironic that a different trade/industry is using them in a different capacity.

Hmmm. Learn something new everyday.

Well, Bob's your uncle. Looks like the insulators stole the squeegee. Found them easily on Amazon searching for "vinyl sign squeegee". Thanks!
 

BamSHO

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The stock box with K&N panel and Airaid seem to be neck and neck. K&N Typhoon looks cool, but gets too much heat soak, and is actually slow. I tested that out last March at the strip during test and tune. Think the bigger issue is feeding the turbos, BullyDog has a nice setup for the trucks. This is a something I came up with to feed little extra air. I have a 3" hole punched in the bottom of the stock box and Airaid.

http://s1290.photobucket.com/user/bamkmm91/slideshow/SHO ram air setup
 

OmaHahn

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I just bought an awesome CAI from MDesign! It's a fully enclosed CAI made out of carbon fiber! And it's a straight tube from the fresh air scoop straight into the engine - I've heard people getting very impressive gains just from this one mod - cannot wait to install mine! Look them up on Facebook, MDesign!
 

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