Jump to content
Sign in to follow this  
GT500R

Fresh Air Intake Mod

Recommended Posts

So taking a page out of Xtra's book on this thread - http://www.fordedgeforum.com/topic/22798-g2-edge-sport-cold-air-intake-hack/?hl=snorkel

 

I decided to check this out and see what the hype is all about.

 

So I took a look at what the current view is for fresh air to go into the air box -

 

f298TDm.jpg

 

 

So the first thing you notice is the hood latch mechanism in the way.... nice Ford.

 

eqPXUQ5.jpg

 

So I tried moving it completely out of the way but couldn't get a good spot, but low and behold there is a lip that sinks down between the inlet and the latch mechanism. So two holes later and it was moved out of the way -

 

Gttb5w9.jpg

 

Now that it was out of the way lets see how it looks -

 

 

DJl8Sfz.jpg

 

 

MUCH better, now that the piece is out of the way, so is the cord (right hand side).

 

But there still is an improvement for the one piece hanging down right in the middle.

 

Take that out and PRESTO -

 

Z8CmBGW.jpg

 

 

Now air can get into the car with no obstacles.

 

Now the real question... so what are the gains?

 

Well, nothing great overall... nothing you will most likely notice seat of the pants, maybe a bit less laggy but I did notice a smidge more timing up top. I notice that the intake temp in the box was down 4* F overall based on 5 average runs previously and just one run with the improved flow.

 

Is it worth it? Well it is a free mod and does remove anything in the way of the intake, so I say it is worth it.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

  • Like 4

Share this post


Link to post
Share on other sites

Nice work man. I am getting ready to do this this weekend. Looked at xtra’s great post and I like the way you gave us a view of the air flow. Now I am fully prepared. ??

  • Like 1

Share this post


Link to post
Share on other sites

I don't think this will work the same for the ST. 

I tried looking but the air intake is covered and not visible at all from the front or top of the vehicle, there's a black plastic piece covering the top and I think the air is taken from the grille below and then up to the air box.

 

I'll try and post some pics next time I look.

Share this post


Link to post
Share on other sites

This is very early and I am letting the cat out of the bag and most of the time that is not a good thing ... I have started to make a mold for a new Sight Shield to increase  air flow to the snorkel .  I have not yet decided as to vacuum form or compost lay up. As this will take some effort to properly design and fabricate I will give updates from time to time as progress is made. At this point it is just an experiment. 

IMG_1844 2.JPG

Edited by Xtra
  • Like 3

Share this post


Link to post
Share on other sites

I see what your doin there. Looking forward to what you come up with

  • Thanks 1

Share this post


Link to post
Share on other sites

Although I posted the finished project in another thread I thought I would follow up with what I started here . 

This is the clay after shaping. I made sure the hood would close and used small worms of clay to check hood clearance. You can see where the closed hood smashed the worms and how much space I have left. I did this every inch across the entire form. 

IMG_1941 copy.jpg

Edited by Xtra
  • Like 1

Share this post


Link to post
Share on other sites

The idea of this is to allow more volume under the sight shield for better air flow. After I covered the clay with aluminum foil and extended the edges with foam core, clear packing tape covered the entire thing as the release agent. Several layers of fiberglass cloth and mat were then applied. 

IMG_1957.JPG

IMG_1983.JPG

  • Like 1

Share this post


Link to post
Share on other sites

Trimmed to shape and covered with bondo it is ready to sand, paint and install.  Although the finish is not perfect it fits well and works with the grill mods I already have. Been using it for a couple months now and it is better than stock according to my butt Dyno .. LOL , and will continue to use it . Now all I need is a " SS  intake "  Thats the snmjim & Special_K intake recently developed and I will have a complete system. 

IMG_1996.JPG

IMG_2010 copy.JPG

Edited by Xtra
  • Like 1
  • Thanks 1

Share this post


Link to post
Share on other sites

:play:"Necessity is the mother of invention" 

Edited by Xtra
  • Like 2

Share this post


Link to post
Share on other sites
On 2/18/2018 at 5:00 PM, GT500R said:

So taking a page out of Xtra's book on this thread - http://www.fordedgeforum.com/topic/22798-g2-edge-sport-cold-air-intake-hack/?hl=snorkel

 

I decided to check this out and see what the hype is all about.

 

So I took a look at what the current view is for fresh air to go into the air box -

 

f298TDm.jpg

 

 

So the first thing you notice is the hood latch mechanism in the way.... nice Ford.

 

eqPXUQ5.jpg

 

So I tried moving it completely out of the way but couldn't get a good spot, but low and behold there is a lip that sinks down between the inlet and the latch mechanism. So two holes later and it was moved out of the way -

 

Gttb5w9.jpg

 

Now that it was out of the way lets see how it looks -

 

 

DJl8Sfz.jpg

 

 

MUCH better, now that the piece is out of the way, so is the cord (right hand side).

 

But there still is an improvement for the one piece hanging down right in the middle.

 

Take that out and PRESTO -

 

Z8CmBGW.jpg

 

 

Now air can get into the car with no obstacles.

 

Now the real question... so what are the gains?

 

Well, nothing great overall... nothing you will most likely notice seat of the pants, maybe a bit less laggy but I did notice a smidge more timing up top. I notice that the intake temp in the box was down 4* F overall based on 5 average runs previously and just one run with the improved flow.

 

Is it worth it? Well it is a free mod and does remove anything in the way of the intake, so I say it is worth it.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

What piece was that in the middle and how did you remove it?

  • Like 1

Share this post


Link to post
Share on other sites

I have been working on molds to make a buck for the intake I designed,  and have completed a couple of attempts without success. Bubbles and uneven mixing of chemicals are a few of the problems I have encountered. I am not deterred and the third time is the charm. I learned so much on the first couple tries I have confidence in this next attempt. 

 

 

Mold ready to release

XTRA CASTING.JPG

 

Top of mold 

XTRA  TOP OF MOLD.JPG

 

 

The molded buck has many flaws in it and it will be easier to make a new mold and recast the Buck than to try and fix this mess. 

XTRA BUBBLES.jpg

Edited by Xtra
  • Like 1

Share this post


Link to post
Share on other sites

Fiberglass and it is messy and smelly. I am making a buck for the air intake I designed

Edited by Xtra
  • Like 1

Share this post


Link to post
Share on other sites

My sincere sympathies.  I had made a spoiler for my Tempo decades ago, but that was a cakewalk compared to this!

  • Like 1

Share this post


Link to post
Share on other sites

Progress is being made, I rebuilt the mold and started casting the vacuum form buck. I believe that I have it figured out now and should have the buck out of the mold by this weekend. It is expensive, dirty work, so this will be my last attempt. 

 

Empty mold ready to go.

mold.JPG

 

 

The first critical layer is done.

start to cast buck.JPG

Edited by Xtra
  • Like 1

Share this post


Link to post
Share on other sites

Added another couple of layers of glass today and it is coming along. I believe I will have a good starting point with this attempt. It will take a ton of sanding and finish work before it is ready to use. IMG_4898.thumb.JPG.67f47644faacddbff76de149c9efd270.JPG

Edited by Xtra
  • Like 2

Share this post


Link to post
Share on other sites

I finished casting  the buck today.. I added  hollow places    So I can drill through and have vacuum to help pull in  the ABS . I floated the last coat  to have a flat even foot that I can finish with a little sanding. Tomorrow I will remove it from the mold. I hope that it is good enough to work with this time. If so, then I will  get a good mask for all the sanding that will have to be done.  😀

23088523-A1A6-4B0C-8C5C-D8A057F862BE.jpeg

Edited by Xtra
  • Like 2
  • Haha 1

Share this post


Link to post
Share on other sites

I pulled the buck from the mold today and did a little rough finish work on it. Sanding makes a huge mess, I had to stop several times to get the dust off of me ☠️. Thank goodness for N95 masks :) Also, had to leave my clothes outside when I stopped sanding and went inside to clean up. I think this buck is going to work fine. 

 

The bottom sanded flat.

Xtra FAI Buck Bottomm.JPG

 

A bit rough but, the top of the buck is ready for Bondo and finish work to smooth out any imperfections and define the lines.. 

Xtra FAI Buck Top.JPG

Edited by Xtra
  • Like 3

Share this post


Link to post
Share on other sites

I cut my right thumb pad while sanding today, darn fiberglass.  The cut does not bother me as much as having to shelf the project for a few days while I heal up some. 

Edited by Xtra
  • Sad 1

Share this post


Link to post
Share on other sites

In all my past turbo car airboxes.... I just took my hole saw and swiss cheesed them. I removed weight--- maybe a couple ounces but absolutely did NOT ADD any... I will also be moving the cable as shown here to increase what little ram air effect that little slit could possibly have... 

  • Like 1

Share this post


Link to post
Share on other sites

Work has resumed, and it is starting to take shape.  

XTRA'S INTAKE BUCK.JPG

Edited by Xtra
  • Like 1

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
Sign in to follow this  

×