BBP's CAI (DIY save $$$)

[badboypolar]

Badboypolar's Cold Air Intake Install with Pictures

Here is my full write up on what to buy and how to install a full CAI that is similar (but quite different) to Dinan's CAI. There are three CAI's however only Dinan's, and now mine, drop the filter in to the wheel well. It is my belief that it is better to draw air from the wheel well. Of course this could be up to debate, and it is only my opinion. So here is how I did it.

Please keep the debating of CAI and filter and what not out of this thread. This is simply an informational post for those who want to DIY.

Piping = $99
Filters = $75
IAT Relo kit = $129

Grand Total = $303

First you need to buy piping. I bought a 3" intercooler kit from EBAY. It came with all the necessary hardware which includes 2- straight pipe, 2- 90 degree bends, 2- 75 degree bends, 2- 45 degree bends, 8- straight pipe adpaters, 2 90 degree pipe adapters and 20 clamps.

Second buy 2 filters. I bought AEM dry flow. No oil and it supposedly cleans up to 1 micron and has a higher flow rate. Again up to debate.

**Optional Step: Buy the IATS relocation kit. I did and you will see where I put it later.

Now with all your pipe laying out you will need the 2- 45 degree bends, 1- 90 degree bend and 1- straight piece. You will use every pipe adapter and 18 clamps.

Start by removing the bumper and be sure to detach everything. On the right side (passengar) you will need to unbolt and detach the air pump. The directions for reinstalling the air pump are below. Also completely remove the stock air boxes.

IMPORTANT NOTES:
- When cutting the pipes be sure to file down the edges and clean the inside of the pipe out to remove any metal shavings.
- The adapters for the trumpt cover you should use the stock clamps as they are larger and will work better.

I am going to make some brackets to hold everything in place. I will update this thread later once I get those made.

Right side (passenger):
First up is 90 degree bend pipe. You will need to cut this 1/2" after the bend on the short side and 4" after the bend on the long side. Then the MAF. Now the 45 degree bend You need the short side cut the 4" from then bend and full length on the other side. Then the 90 pipe adapter. Now you need a 2" to 2 1/2" piece of straight pipe. It should fit so that the air filter and 90 degree bend are butted up againest each other. Now you will have to flip the air pump upside down and use the middle mount and bolt it to the front most mount.

Left side (drivers):
First up is the 90 degree pipe adapter. Now a 4 3/4" piece of straight pipe. Then the MAF. Now the other 45 degree bend cut to 5 3/4" after the bend and full on the other side. You'll need a 4" piece of straight pipe then the filter.
Optional IATS relocation:
I installed my IATS relocation kit in the straight piece before the filter. I used a rubber IATS adapter from an Intake from a Honda Civic. It screws right into the rubber housing. If you do it this way you'll need to drill a 5/8" hole though the pipe and push the rubber adapter in. I wanted it inside the intake track that way I know it is at least measuring air on the way to the engine. Otherwise you could just install it where ever you want.
You can find the rubber adapter at NAPA auto parts by itself. You might be able to also find it at autozone or kragen by itself I am not sure. I know you can buy one of the $20 intakes for a civic and use the IATS rubber adapter from it.

Picture time:


















Enjoy!

[Evil One]

Very nice! I'd like to try to do something like that, but I'd use blackened plumbing to keep a more 'stock' look.
Do you hear more intake noise (windows up & windows down)?
Did you feel much of a change in the behaviour of the car?
Anyway, well done

[E55AMG2]

hmm.....I might do this, but with plastic piping to avoid heatsoak

[claymax]

Nice write up and great pics too. Even if it's not exactly what everyone would do it's still nice to see how to do it and what you did.

Good job, looks well done.

[mchin]

Great job and write up.

Can anyone tell me if the Dinan set up terminates in the same location. From the pics I have seen of the Dinan set up it appears that this is exactly the same.

Also, E55AMG, would a plastic (PVC) set up work well to get rid of the heat soak problem in your opinion? I always thought that Dinan used CF b/c this dissipated heat better than plastic or aluminium?

Thanks again for the info.

Michael

[WizAlex]

BBP,
Very nicely done! Did you have to take the front bumper off? Is it easy to take off/put back on?

Also, I was thinking, don't you want the piping, pipe diameter and all that to be the exact same on both sides so that each side gets the "same" amount/rate of fresh air? Looks from the pics that the last segments into the engine itself are a little different on each side. Is that the case or am I dillusional?

Great job again!

--Alex

[badboypolar]

The pipe is different on each side because it has to be. The left side if you go too far out you will hit the fan. On theright side you have to go further out otherwise it won't fit properly because it will hit the engine. It is a very tight engine bay. The piping is the same exact size of 3" diameter. The length is shorter on the left side because of necessity. There is no where else to put the filters.

[mchin]

Here is a link to a vendor for silicone tubing to use for the plumbing.

http://www.siliconeintakes.com/categ...f6a5630f1821e1

This was posted in another thread about the AEM filter.

regards

Michael

[EM5PWR]

nice job... i'd prefer black over blue though .

mchin, dinans cai does end in the same location...

[SoCalJD]

Originally Posted by claymax

Nice write up and great pics too. Even if it's not exactly what everyone would do it's still nice to see how to do it and what you did.

Good job, looks well done.

>>>

Right? Dude's like, 16, and not only did he do that himself, but he cooked us some killer ribs in the process. Very impressive.

[badboypolar]

Ahh I wish I was 16. My knee's would not have hurt so bad after all that.

The car seems to run much smoother now with the intake and I do notice some more power. How much I don't know as I did not do a baseline dyno before the install.

[mchin]

Hey guys board member 6Spd has pointed out that the tubes I referred to are not rigid but flexible with reinforcement. I did not realize this and I apologize if anyone here was mislead by my reference to the site.

Fast4door thanks for the information.

regards

Michael

[E55AMG2]

Originally Posted by mchin

Great job and write up.

Can anyone tell me if the Dinan set up terminates in the same location. From the pics I have seen of the Dinan set up it appears that this is exactly the same.

Also, E55AMG, would a plastic (PVC) set up work well to get rid of the heat soak problem in your opinion? I always thought that Dinan used CF b/c this dissipated heat better than plastic or aluminium?

Thanks again for the info.

Michael

Dinan used CF because Dinan wanted to use CF. Carbon fiber is about the same as thick plastic for thermal retention...but it looks 100% cooler