Xtra

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. 

On 4/26/2023 at 8:30 AM, Willy41 said:

I'm looking to buy v2 intake cover for 2016 ford edge sport?  Possibly this Breather?  Let me know thx leo 

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.

1 hour ago, Perblue said:

I need to find who makes the down pipes and get them ordered.

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. 

52 minutes ago, Perblue said:

Also slowly getting ready for 3l swap.

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

The right angle air disc sander removes most of the material.

But leaves a rough finish

Using the razor to scrape the ABS cleans up the tool marks. 

The finished and polishes edge.

Before and after. This completes the shaping of the Adaptor. 

The next step is to clean up the third cut, it takes about 45min to an hour to complete. .

This return lip must be removed for the intake to move air smoothly with no restrictions

Before and after.

The clean up is done with these three tools.

Although the third cut is the easiest to make. It requires the most amount of hand finishing of the 3. This is done to provide the maximum air flow and least amount of resistance.  

This is the final cut on the Adaptor. It now has been cut out of the ABS Vacuum Form sheet and is taking on the final shape. There is still a long way to go before it is a useable part. 

New much shorter video

This video shows the process of how the second cut is made. Each step requires a different jig. At first, before I had jigs made, I would draw a line then cut wide and hand file and sand to the line. This had to be done during the design phase. Creating  jigs that could produce repeatable accurate results was critical to the V3 project. It took a lot of time and work to get to this point where there is a complete set of V3 jigs. But it was worth it, the jigs are a huge timesaver and increases the quality of the V3. 

Making The Second Adaptor Cut...  Trimming to finished Height. 

Finished the second cut trimming all the Adaptors today . 

Before and after the cut,  before finishing on the belt sander

This is what is removed. It sets the correct height of the adaptor, and removes the flange around the edge. 

Feeling better and got back to work on the Adapter today.

I have a few CF V2 in stock. These are the last of the CF V2 as the material to make them is no longer available. As such I am closing them out at a substantial discount.  $40 off on  all remaining CF V2 . Once they are gone only the ABS will be available.  Fits 2015 to 2018 Edge -- All models and engine combos. 

PM me for more info.

On 4/26/2023 at 8:30 AM, Willy41 said:

I'm looking to buy v2 intake cover for 2016 ford edge sport?  Possibly this Breather?  Let me know thx leo 

Check your private message  

I need to take a break for a few days as I caught some kind of bug. While I am not bedridden I am not well enough to work around power tools safely. I hope to be back at it next week at the latest. It is not Covid I tested negative. 

As promised was able to cut out the Adaptor blank from the ABS. . 

First thing to do is drill two mounting holes. 

This is what it looks like after removing the blank from the ABS

Video of how it is done 

Tomorrow I will cut out the Adapter blank from the vacuum formed ABS. Perhaps even a new short video of the process. 

Only after everything is aligned, double checked and locked down tight, can the lid be drilled. 

The finished hole, clean cut and ready for the next step. 

The jig is clamped to the crossvise on the drill press and is aligned . It has to be aligned up and down, right to left, and in and out. The clamping board aligns the lid to the drill so that it is parallel  to the base of the lid.