So after coming on here and constantly asking questions of people I've decided to add something constructive to hopefully help people out.
I had a crack at a custom air box over the weekend and am most of the way through it, I just need to finish the lid and give it a coat of black paint and it'll be done.
I figured this is something people ask about quite often and to be honest it's not that difficult.
This is in preparation of my forged 4g93t going into my Satria GTi in the next couple of months, I will not be running an air flow meter and will have a 4" pipe running directly to the pod filter.
Below is an image of my current setup, the filter and battery will be swapping positions when the new engine goes in.
First I created a cardboard template to fit in behind the headlamp, I'm using the bolts that held the batter tray in to hold the box in place. Having a 4" intake pipe, I've made the hole 110mm diameter so that I have room to run a rubber strip around the inside of the hole to prevent it rubbing.
Different angle...
Then traced the template onto aluminium sheet and scored and folded to fit...
I riveted some aluminium angle to the top of the box for the lid to be screwed onto, this also helps make the thin aluminium a little stiffer and rigid.
I used a larger profile of aluminium angle on the inside of the box to help stiffen it to avoid flex and hold everything square...
And the outside of the box...
I then created a template for the top of the box to seal it all off. The final product will be painted matte black so this gives a good indication of how the box will look from the top once painted.
From this angle you can see that the aluminium will be folded down behind the radiator overflow for a neat finish.
And that's where I'm up to, this weekend I'll be cutting and shaping the lid, I'll also be running rubber bead around the hole to protect the piping and across the front of the lid so it doesn't rub against the frame above the headlamp.
More to come after the weekend...
I had a crack at a custom air box over the weekend and am most of the way through it, I just need to finish the lid and give it a coat of black paint and it'll be done.
I figured this is something people ask about quite often and to be honest it's not that difficult.
This is in preparation of my forged 4g93t going into my Satria GTi in the next couple of months, I will not be running an air flow meter and will have a 4" pipe running directly to the pod filter.
Below is an image of my current setup, the filter and battery will be swapping positions when the new engine goes in.
First I created a cardboard template to fit in behind the headlamp, I'm using the bolts that held the batter tray in to hold the box in place. Having a 4" intake pipe, I've made the hole 110mm diameter so that I have room to run a rubber strip around the inside of the hole to prevent it rubbing.
Different angle...
Then traced the template onto aluminium sheet and scored and folded to fit...
I riveted some aluminium angle to the top of the box for the lid to be screwed onto, this also helps make the thin aluminium a little stiffer and rigid.
I used a larger profile of aluminium angle on the inside of the box to help stiffen it to avoid flex and hold everything square...
And the outside of the box...
I then created a template for the top of the box to seal it all off. The final product will be painted matte black so this gives a good indication of how the box will look from the top once painted.
From this angle you can see that the aluminium will be folded down behind the radiator overflow for a neat finish.
And that's where I'm up to, this weekend I'll be cutting and shaping the lid, I'll also be running rubber bead around the hole to protect the piping and across the front of the lid so it doesn't rub against the frame above the headlamp.
More to come after the weekend...
