EASY $30 DIY Cold Air Induction!

[Mayhem05]

And even better if wraped with a heat reflective adhesive tape like used on air cond ducts

[Nackerz]

Cold air intake is a basic way to gain a little bit more power and efficiency.
The idea is simple, the colder the air into the engine the better because the colder the air the more dense it is. (Unlike the hot air in the engine bay)

All the things you will need you can get from Bunnings or most hardware store

I bought:

1. A 90mm stormwater pipe that was 90mm diameter - $5.30
2. 2 90mm stormwater "Female and Female" 45deg bends - $1.51 each
3. silicon (Bond & Seal) - $5.74
4. 3/16 washers (50 pack) - $3.13
5. 3/16 nut and bolts (20 pack) $3.30
6. 90mm hanging bracket (get 2 in a pack but i used only 1) - $8.46
7. 90-105mm steel hose clamp - $4.46

Total $33.41

You will also need some assorted hand tools.
Read through to find out.

Step 1.
I took the top half of the air box off and left the bottom, then marked where I was going to drill through the hole already in the bottom of the box which is right above the drain hole in the guard... So I could drill through it without it pushing through I screwed some self drilling screws through the tabs.

Step 2.
Then I drilled through the tab on the mark that I put there before (this will act as a guide for the whole saw)
Then I refitted the air box.

Step 3.
With an 89mm Hole saw cut through the bottom of the air box. The 90mm pipe will be a tight fit so you will probly have to file some off around the edges for a nice tight fit

After filed it’s an air-tight fit

Step 4.
Now using a 103mm Hole saw cut through the guard using the pilot hole you drilled before (Make sure you use a good quality hole saw or you will have a lot of trouble and chew the teeth off the saw)
With a 103mm hole it allows for movement without hitting or vibrating on the body of the car.

Step 5.
Dummy up the pipes to how you want. I had three lengths,
They were aprox:300mm
150mm
70mm

The 300mm pipe goes from the guard to the first 45deg bend then the 70mm one goes between that and the second 45deg bend and finally the 150mm pipe goes up into the air box

Step 6. When your happy with the way your pipes are angled and setup. Glue them together and work out a suitable place to mount the bracket, and twist or bend to suit.

Step 7.
Now with the box, make to right angle brackets tho support the pipe inside the box… rivet one side to the bottom of the box. At the same time you car cut a piece of metal to fill in the original air duct hole. Rivet that over the hole and put silicon around the edges (if you do it on the inside of the box you can paint the outside, cause the paint will come off the silicon.

Step 8.
To keep it less obvious paint it black. (I also think it looks better)

Step 9.
After its all dry, I put a bit of flyscreen over the end to prevent big things like bugs and rocks getting in. then you can bolt it all up and make sure its all secure.

Step 10.
Put the rest of the air duct back on, then drive and enjoy… for best results use a high flow air filter (stock VLs use A360 filters)

If you need any help or better pics pm me

heres a link to cai on wikipedia to tell you about the advantages


NOTE:
I’m not held responsible for any of this that gets put into your car… it is your choice to make this system and your problem if you get defected/booked

Also for any injury you sustain or damage done to your car while fitting/fitted this to your car!

AND NOW YOUR CAR WILL NOT PASS A ROADWORTHY.....end of story piece out

[JST-23Z]

AND NOW YOUR CAR WILL NOT PASS A ROADWORTHY.....end of story piece out

you silly fool! read the rta website or the rta book... its ok to put a hole here as its not a structual part of the car... get ya shit straight

[Nackerz]

yeah and my mechanic has told me that it will not pass a roadworthy

oh i just seen that your in sydney....well im in vic and it wont pass a roadworthy down here mate

[JST-23Z]

ok well im from nsw and a mechanic

[Nackerz]

ok well im from nsw and a mechanic

Yeah but are you licenced for doing R.W.C, because some mechanics cant do roady's as there not licenced too...

yeah well im my own mechanic lol

[JST-23Z]

only pink slips (annual rego) but not blue slips

[s_ikari2015]

If you're really concerned about RWC and cutting holes in the body then do the MCAI two hole trick, remove the left headlight and route a pipe/channel through to the grille infront of the radiator.

I'm going to do something like that for my Monaro because I want something that's standard looking without paying hundreds for an SS kit that's not worth it. I'll keep everyone posted on the progress.

[d mon]

i like what im seeing

[bottleinspector]

great thread...dads a plumber so i think ill head up there right now and get heaps of his gear....just a couple of quick question.
1. should i block the OTR intake off?
2. would 120mm or 150mm be even better?
car is a Vs 5L
cheers

[JST-23Z]

great thread...dads a plumber so i think ill head up there right now and get heaps of his gear....just a couple of quick question.
1. should i block the OTR intake off?
2. would 120mm or 150mm be even better?
car is a Vs 5L
cheers

i would proberly block the otr off but i thought they were pretty good in the vs. u may have to ask someone that knows the vs better than me...
also im not quite sure about the 120 & 150 ones i would assume bigger is better... but in saying that i may very well be wrong. going on the same idea of exhausts, if you go too big it will be worse but once again im not sure... just have a play around with the different sizes if your dad doesnt mind giving you some extra pipe

[Tuff-VP-Wagzz]

if you had a lowered car, would the pipping get in the way?

[JST-23Z]

nah mate no chance of it getting in the way

[stuffedifiknow]

would this mod work like forced induction.

[JST-23Z]

would this mod work like forced induction.

no, nothing like it mate

[magoo]

great job....! im in the process of putting a similar one in my ute i put up photos of the finished product.....

[magoo]

If you're really concerned about RWC and cutting holes in the body then do the MCAI two hole trick, remove the left headlight and route a pipe/channel through to the grille infront of the radiator.

I'm going to do something like that for my Monaro because I want something that's standard looking without paying hundreds for an SS kit that's not worth it. I'll keep everyone posted on the progress.

hey mate how did you go with that mod.? im in the process now..!.

[Grouse-mouse]

Holden spent the big bucks and everyone else says do this do that,riddle me this...why put a cold air intake over the top of a radiator which radiates heat??more air equals more fuel..simple.

[VSSS_5L]

I have an OTR CAI, but i also have a patch in the bottom of my airbox, and under the airbox a NASTY looking dodgy cut hole. Is it worth using that ugly ass hole to add one of these with the OTR CAI as well, so 2 CAI's really?

[azkwazere]

If the hole is already there then why not - the more more cool air you can force into the airbox the better.

aZk.

[^_^ Gem132]

dont want to bring up an old thread, but i live in sydney (blacktown area) and i want to do this to my vl as i just put a k&n panel filter in, are you guys 100% sure this will pass a roadworthy as i dont want to do this than it not pass ?

[Munz]

I doubt it will pass if they see it.....unless you know your mechanic really well!!

[wraith]

People still do this stupid dodgy air intake. Yuck. Now day's any extra holes that have been drilled in those areas attracts attention.