Xtra

Adding the Aux Air Intake to the V3 lid. Once the Aux Air Intake Port is installed, the next thing is to deal with the Sensor Port.

This video is a bit out of order as this work was done before the Adaptor was finished. Once the saw was setup all the aluminum parts were cut on the same day. Cutting the Aux Air Intake blanks to length from a tube of 6061 aluminum.

Fabrication of the hinge clip and installing it completes the V3 Adaptor. Working with Aluminum is is way different than ABS. Everything on the V3 CAI is rust proof it's built from Stainless Steel, Aluminum and ABS. Now that the Adaptor is complete it is time to work on the Lids and finish up the Aux Air Intake and Sensor port. This video shows the completion of the Adaptor. These little hinges take a lot of hand shaping, filling, polishing and time to get correct. The results are worth it .

That is an awesome combo of suspension parts. Not only do they make the car look great you will be surprised how well it will turn corners now. If you live where there are any curvy, twisty roads you should go there and have some fun. The car will also be safer at highway speeds if you ever have to make an emergency lane change it will be up to the task.

Now that the Adaptor to OEM air box side is finished. It is time to flip over the Adaptor and start on the Adaptor to Lid side. it starts with installing the C-Clip.

Now it was time to test fit the Adaptor to the OEM air box. Checking to see.... 1. How well the Tabs align 2. How well the high density foam gasket seals 3. How tight the J hooks clip in. 4. How tight the Adaptor fits to the OEM air box . If there is any wiggle or slop 5. If the Adaptor sits flat, and even

The "J Hooks" are attached next while the jig for the Tabs is still in place. I call them J Hooks because of their shape. The J Hooks installed. They are used to give the bottom half of the OEM air box something to clip to. You are looking at it upside down as compared to when it is installed in the car. The completed bottom of the Adaptor with the Tabs, J Hooks and gasket installed.

Time to add the Tabs to the Adaptor. It is easy, but I have to be carful not to make a mess. The bottom half of a brand new OEM air box was cut up and sacrificed to make another jig for the Adaptor.. Converting the OEM air box into a jig insures that the tabs will be set correctly. The jig is taped down tight to the Adaptor to lock it into position, and to insure it does not move while working with it. The glue I use melts the ABS creating a weld when dry. The 3 Tabs installed waiting to dry.

Willy41 Ihave sent you an PM and offered you a great deal. To view it, click on the envelope icon at the top right corner of this page next to your name. To anyone interested in a V2. I have a few Carbon Fiber material V2 remaining and these are the last of them. The CF I have been using is no longer available and I am selling the ones I have at below cost to make some needed space.

Now, flip the Adaptor over and install the gasket that seals it to the bottom of the OEM air box once installed. The high density foam gasket. This lip that the gasket adheres to O.D. is made smaller so that when the gasket is installed the O.D. is correct and it will fit tight and seal into the OEM air box.. The Adaptor with top and bottom gaskets installed. Ready for the next step... installing the clips and latches. It is now taking shape and looking more like a part.

The next step is to add the edge protector. This not only gives a finished look to the Adaptor, more importantly it seals the Adaptor air tight to the high density foam gasket on the lid. This edge guard is the best I could source with grips on both sides in the middle and metal clips molded into it It is cut to length and the Adaptor edge is cleaned before installing Ready to trim to length. It is easy enough to cut the material, but I only get one shot at it . Cut to short and the Edge guard has to be tossed. Cut a fraction to long, and when it is trimmed, more offer than not the edge is frayed making for a sloppy joint. This one I nailed spot on; The finished edge protector installed.

The clean up of the Adaptor. This completes the process of cutting and shaping the Adaptor from the ABS vacuum formed sheet.

Snmjim took the platform to the max and knows all the weak points and how much power different parts can take.. He can tell you exactly how much you can make safely. And what needs to be beefed up and when. He did not post everything he learned.

I guess you know check the Ultimate 2.7 Parts thread . You could be pushing the limit of some drive line parts depending on how much power you make. I would contact snmjim for some information that could save you some time and money with this swap.

Nice, those make great power right out of the box. And what the Sport and ST should have had from the start.