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Make your own CAI!
Posted: Fri Jun 07, 2002 1:20 pm
by d_m_kolb
I have copied and pasted all the info in this link because half the time the website would be down so hope this helps.You can also use header wrap on the CAI to make sure the air temp stayed down.I put my MAF sensor in the CAI and used (form a gasket) to hold the air temp sensor in the piping.This is the K&N filter part # I used. RX-3820It's one of their new filter designs Universal X-Stream Clamp-on. It's a cone filter but also sucks in air from the very top of the filter unlike most.Here's a link to the filter
http://www.knfilters.com/universal/X-stream.htm Here are some pics of my custom CAI.Here are a few pics of the K&N filter I used part # RX-3820. You can see the Air temp sensor installed in this pic. This is a pic of the filter installed under the car. You can see the filter through the front air vent of the car. This is looking through the above air vent in the front of the car. Here are a few full few pics of the CAI. You can see the MAF sensor installed about 4 inches before the TB. The AEM cold air intake is hands-down, the absolute best intake system on the market – period. Dyno result after dyno result proves that this system makes the most power of ANY intake system on the market PERIOD – more than Iceman, Weapon R, RS Akimoto, PRM, etc. There are a number of reasons for this; the main reasons include how the system was engineered overall. AEM "tunes" the system to each application - the length of the overall tubing, the diameter of the tubing, and the minimal number of bends all work together to make this system create the maximum power from your motor. The smaller, 2.5" single-diameter tubing helps increase the velocity of the air flow, and the placement of the air filter ensures that the coldest air possible will be drawn in. This colder, faster air is what allows the AEM CAI (cold-air intake) to make maximum power on Honda and Acura engines. There are a few problems with the AEM system, however. The first is that it’s made of aluminum. Aluminum is lightweight, but is also an excellent conductor of heat. Thermoplastic and silicone would be better, like the Iceman and PRM systems, but steel works as well as aluminum (better in cact) with only a small weight increase over aluminum, plastic, or silicone. The AEM systems are ceramic coated, which helps block heat, but they only ceramic coat the OUTSIDE. Another problem is price – the retail price of an AEM system is $250. I have found a way to make an AEM-style intake, for 1/4th of the cost. I have not dyno tuned this new intake, but in swapping out my old AEM intake for my version, I can tell you that I have not noticed any power loss whatsoever. In fact, the new system feels stronger than the AEM system did. I will explain the reasons why I think my system makes slightly more power than the AEM system later in the article. Here’s what you’ll need: 180 degree mandrel-bent piece of steel tubing – see notes below (4) rubber PVC pipe clamps – see notes below K&N "Funnel Ram" Filter – see notes below (1) can of Plasti-Coat ceramic high-temp engine spray paint – see notes below 3/8" ID rubber grommet, 3/8" OD piece of plastic tube (about 4" of tube), 5/8" OD (3/8" ID) piece of vinyl hose (about 12" of hose) – see notes below Flathead screwdriver Hacksaw or air cutting wheel Electric drill with 3/8" drill bit. Metal file and sandpaper The toal cost of the project is about $60 - $70 depnding on shipping prices, the brand of filter you buy, etc. * Notes: - First, the tubing. Believe it or not, the tubing is a piece of mandrel-bent tubing from J.C. Whitney! It’s a "180 degree u-bend". I paid $17.98 for mine. Call (312) 431-6102 and order part number 81EH3035N. This single piece of pipe will be used to make the entire CAI system! (The piping is slightly heavier than the aluminum AEM system, but we are only talking about a pound or so and the power gains and price savings from this system more than outweigh the pound you will gain with the steel piping!) - The rubber pipe clamps can be purchased at any Lowe’s Home Improvement Store. They are made of durable, flexible, high-temp black rubber, and already have (2) stainless steel clamps integrated into the clamp. Go to the PVC plumbing section, and look for "PVC Pipe Clamps". The ones you need are for 2" PVC pipe. The clamps cost $4 each, and you will need (4) of them. - On the filter, you can order K&N filters from just about anywhere. The price varies from $20 - $50 dollars. I paid $30 for mine from
http://www.martelbros.com It’s a 6" filter with a 3" opening and includes a built-in funnel-ram velocity stack. Other good choices are RS Akimoto filters with both an internal aluminum and built-in velocity stack. You can also order an AEM replacement filter direct from AEM (or any AEM dealer). I do not know the exact price, but it shouldn’t be more than $40. The AEM filter will provide the best fit, since they are basically the only company that uses the smaller 2.5" diameter piping instead of the more common 3" piping. With the 3" filters, you will have to use one of the pipe clamps as a step-up adapter, where the AEM filter would bolt right on and fit perfectly. - As far as the ceramic paint, go to any Auto Zone or Wal-Mart store, and buy "Dupli-Color" brand high-temp engine paint. I would recommend using this brand of paint because it does NOT require the use of primer. This paint is also good stuff because it is actually ceramic-based, which greatly helps block heat. The paint runs about $3 a can and you will need (1) cans. I used "Aluminum" color because it matches the AEM color perfectly. You can use any color you want though. - The grommet and hoses will be used to make the crankcase vent system. You can buy the parts at Lowe’s when you are buying the PCV pipe clamps. I got the hoses in the plumbing section, and the grommet in the hardware section. The plastic hose is a milky white and is hard plastic. You only need about 3" of it, but you have to buy it by the foot. The vinyl tubing is clear, although any color will work. You will need about 1 foot of tubing (12"). That’s the end of the notes. Let’s move on to the install. ADDING AN INTAKE Now, take your muffler pipe and clean it up using soap and water. Mine was covered in grease used for lubrication during the mandrel-bending process. Once it is cleaned off, make sure it’s dry. The first step is to cut the pipe. The top bend is the easiest to do first (i.e. the one that connects to the throttle body). You can see from the following picture that the angle matches the stock intake angle perfectly. You can use the stock upper piece as a rough guide for making the cut. I laid the pipe up against the throttle body, and eyeballed the proper angle that the pipe needed to be cut at. Sorry, I don’t have an exact degree for you, but the object is to line up the straight part of the pipe with the hole that goes from the engine bay down into the bumper (where you removed the resonator pieces from). You’re going to have to use your imagination and a little creativity here, but it’s
not hard. See the following picture:
Re: Make your own CAI! (d_m_kolb)
Posted: Fri Jul 26, 2002 2:52 am
by d_m_kolb
Use a hacksaw or cutting disc to make the cut (make sure it’s straight!!). When finished cutting, clean up any rough or sharp edges with the metal file and sandpaper. Now double-check everything by installing the first rubber pipe fitting onto the throttle body. It’s a VERY tight fit, so it will help to lubricate the fitting using a rubber friendly lubricant like silicone grease or even a little bar soap (wet your fingertip and rub a bar of soap). You will have to wrestle it on, but it does fit, as in the following picture: Once you have the fitting on, insert the pipe and clamp it down. Make sure the straight part of the pipe goes perfectly towards the opening to the bumper where the resonator was. One thing to note here. Those worried about hydrolock and water, can convert their CAI into a "dry" system by simply bolting the filter onto this short piece of pipe. This is useful during rainy or winter months. See the picture below: Once you are satisfied with the first piece, it’s time to complete the rest of the system. Once again, imagination and creativity come into play here as I cannot tell you the exact cuts to make. I had to redo a few of the cuts to get everything to line up. Remember to clean up all of the edges with the metal file and sandpaper so you don’t cut yourself and/or damage the rubber pipe fittings. Use the following pictures as a guide on where to make the rest of the cuts:As you make each cut, keep assembling and test fitting the entire intake system. Attach the second pipe to the first pipe still attached to the throttle body, and make sure the second pipe curves down into the bumper hole. Then attach the third pipe to the second pipe and make sure it makes a curve in the opposite direction. You will have to attach the third pipe from inside the lower bumper opening. After you rearrange the pipes, the entire system should look roughly like the following pictures:You can assemble the whole system outside of the car using the fittings and the filter. It should look like the following pictures: (The AEM air filter and it's orange fitting was used during the prototype process...)Once the system looks like the pictures, and you have test fitted everything, it’s time to finish the job. THIS NEXT STEP IS VERY IMPORTANT!!! This step involves making the crankcase vent that goes from the intake system to the valve cover (i.e. crankcase). You need to do this part – it cannot be left out! Anyways, all you will be doing is drilling a 3/8" hole into the upper (i.e. first) intake pipe. Look at the stock piece (and also the pictures) to see about where the hose needs to go: It will be easiest to start with a small drill bit and move up to 3/8". Make sure you make the hole facing the valve cover connection! Once you have drilled the 3/8" hole, insert the 3/8" rubber grommet. Then cut a 3" or so piece of the milky white 3/8" OD plastic tube, and insert it into the grommet. Make SURE it is a very tight fit, basically airtight. It might even be so tight that you need to lubricate the tube to insert it into the grommet. Insert the tube so that about 1" is inside the pipe itself, and 2" is outside of the pipe. Once the tube is in the pipe, attach the 5/8" OD (3/8" ID) tube OVER the milky white plastic tube, and attach the other end to the vent on the valve cover. You may need to shorten the length of tubing to fit. Make sure it’s not stretched too tight, but not too much slack either. Also, make sure the tubing isn’t kinked - this will restrict arflow.Once the tubing system is complete, remove the tubing pieces and the grommet. * Note: If you are making this system for an OBD-II car (i.e. 1996+), you will need to make a place for the intake air temperature sensor. See the additional notes section at the end of the article for more information before continuing! You're almost done...the next step is to paint the system. Get everything cleaned up again using soap and water, or a good engine degreaser or cleaner. Finally, rub it all down with isopropyl alcohol to remove any hand and finger oil. Once you have done so, it’s time to paint the system. This is a VERY important step. Why? Well, the piping is made of plain mild steel, which rusts. The good news is that this piping has been aluminized because it was originally designed for use as exhaust piping. This is to our advantage, because the aluminization will help fight off rust caused by rain moisture and winter salt. However, the edges are exposed steel, and will rust. Also, the ceramic-based paint will help block most of the underhood engine heat, and painting the inside of the pipe will help to smooth the interior. This will speed up the airflow which is a good thing. YOU WILL BE PAINTING THE INSIDE AND THE OUTSIDE OF THE PIPING!!! Paint the inside of the piping first, using light coats. You will have to be creative here, and shoot the inside of the pipe from both ends to ensure the entire inside of the pipe is covered with paint. Make sure you keep moving the can, and don’t spray too heavily, which will cause BAD paint runs and also reduce the overall inside diameter of the piping. I painted the inside of my system with a total of about 3 light coats of white. Let it dry for a few hours, and come back and reclean the outside of the pipe with the isopropyl alcohol to remove any hand or finger oils. Then carefully paint the outside of the pipe using light coats. You will have to flip the pieces over to make sure you cover the entire pipe, or you can just suspend the pipe from a piece of string (allowing you to paint the entire piece of piece at once without flipping it over to do the other side.) I used about 4 coats of paint on the outside. You will be able to handle the pipe after a few hours or drying, but I would HIGHLY recommend even letting the paint dry overnight, as it takes some time to cure. Follow the instructions on the can of paint for the exact details. Once the system is completely dry, it time to finish up. You will start by CLEANING THE INSIDE OF THE PIPING!!! Anything inside of the piping (i.e. dust, metal shavings, loose paint, etc.) will get SUCKED RIGHT INTO YOUR ENGINE when you start the car! This is BAD if you didn’t guess. The easiest way to do it is to run a medium sized towel into the pipe, and pull it through the other end. The towel will pull any loose particles with it and leave the inside of the pipe clean and ready to go. Once the piping has been cleaned out, reinstall the grommets and insert the milky white 3/8" OD plastic tube. Then assemble the intake system and install it. I had to install the upper two pieces first, and then bolt the third piece and filter on from underneath the bumper opening. See picture: (The filter used here is a "funnel ram filter" used during the prototype process...)Hang on, you’re almost done!! The completed system should look like this picture: (The filter used here is the AEM filter again used during the prototype process...) If your system looks like the pictur above, you did it right! If not, you must have missed a few steps ;0) Don’t forget to hook up the vinyl tube that goes from the intake pipe to the valve cover vent!! Finally, put your bumper back on, clean up, and go out for a test drive! You should feel a SIGNIFICANT difference in power across the entire power band. I will dyno my car soon with the new system and report the results. If anyone has a chance to do so in the mean time, I would love to see the exact figures. ADDITIONAL NOTES: The procedure above applies to OBD-I cars. Starting in 1996, Honda added a second intake air temperature sensor in the upper intake tube for OBD-II. So if you are making this system for a 1996+ car, all you need to do is buy an additional grommet ( I don't know the exact size so you'll have to look) and drill a second hole in the intake tube for the intake temperature sensor. Look on the stock rubber tube to see where the sensor is located, and drill the hole in roughly the same spot. Then just insert the grommet + intake temperature s
ensor and secure everything and you're done! The intake piping listed is 2.5". For larger motors (Type R, H-series motors, and even non-intercooled turbo cars), you can use 3" piping. It's also available from J.C. Whitney and runs $21.98. Order part number "81EH3036T" instead of the one I originally listed above if you want 3" piping instead. I would not recommend using the 3" piping on smaller motors (like 1.5 and 1.6L etc.) because you will lose a lot of the low and mid-range power that the AEM system was specifically designed for. Also note that if you use 3" piping you will have to make sure to get a K&N filter with a 3" opening (i.e. the AEM filter will not work). This intake system was designed and prototyped on my 94 delSol VTEC. Depending in the car you are trying to make the system for, it may not work at all. Some throttle bodies are located lower or higher than mine or even orientieted in a different direction! So just because it worked for my motor doesn't mean it will work for yours. One tip would be to look at the AEM system for your car - if it does not roughly resemble my system, then these directions probably won't work. There has been some concern about the steel piping used. The main object of this How2 was to make a system that outperformed the mighty AEM for 1/4 the cost. You can use aluminum if you want - finding the U-bend piece might be the problem (it will also cost more). If you can find aluminum, make sure it has the same u-bend dimensions as the J.C. Whitney piping, otherwise the length and bend angles won't work out the same. The dimensions you need for the 2.5" piping are 18" minimum leg length, 5" radius, and a 180 degree bend. The dimensions for the 3" piping are 18" minimum leg length and 6" radius. The bend on both pipes is 180 degrees obviously. (The J.C Whitney piping has a 24" leg length, but there is leftover piping that you do not use). DO NOT use PVC pipe to make the intake piping. PCV piping is not heat tolerant and will melt and release toxic fumes when exposed to under hood temperatures. Plus the ID of PVC piping is much smaller than 2.5" because it is very thick. The Iceman systems are made of thermoplastic, which is a special plastic formulated to take heat. PVC piping is not so please do not use it. On the crankcase breather tube, you do not have to use plastic tubing. You can use a piece of 3/8" metal tube instead and have it welded (or JB Weld it) if you want. I just chose plastic tuning because it's the easiest and cheapest and doesn't involve welding. Finally, some of you have been curious about the ceramic paint vs. the AEM vs. the Iceman. I had an AEM intake for 2 years, and I have a friends with Icemans. We did a test, which involved driving in stop and go traffic for about an hour in 70F degree dry weather. Once the under hood temperatures were good and hot, we popped our hoods. We felt the upper-most portion of the pipe, because that is the section of the pipe exposed to the most heat. The AEM pipe was VERY hot, almost so hot it hurt to touch. The Iceman was hot as well, but nowhere near as hot as the AEM. My intake system with the ceramic paint on the outside and inside was cool to the touch - I am not kidding. The exact words my friend (with the Iceman) said after feeling my intake was "damn, that's cold!" I don't know if it was that cool because the piping is steel or because it is double-coated, but basically I am telling you this so you are not hesitant to use the steel piping because it will "get hot". It won't.
Re: Make your own CAI! (d_m_kolb)
Posted: Sun Jul 28, 2002 11:13 pm
by VibeInTx
I have always wondered: if moding the intake is so easy an inexpensive, then why wasn't the car designed that way to begin with? What are the drawbacks of moding an intake (i.e. why wasn't it so in the first place)?
Re: Make your own CAI! (VibeInTx)
Posted: Mon Jul 29, 2002 1:40 am
by d_m_kolb
No one said it was easy. When I made mine It took me the better part of a Saturday to get it done. If you don't know what your doing your car will probably not end up running right. I'm not trying to scare anyone but a little thing like installing your MAF sensor in backwards will cause your car to run carppy. I had to cut the wires to my Air Temp sensor relocate it and rewire it again. It wasn't hard but again if you have never done this it could couse you problems.The reason CAI don't come from the factory is mainly dew because of noise. They make the stock intakes to keep noise levels down but this is very restrictive and hurts performance. The more restrictive a intake the harder a engine has to work to suck in the air taking away from the power it could be making with a less restrictive set up. Also a stock intake has resonators that cancel out noise so it's not loud when your accelerating but these are very restrictive them selfs. A aftermarket or custom CAI has no resonators and very little restriction alowing the engine to suck in more air easier resulting is more power through out the entire RPM range.Another draw back to the stock plastic intakes is they transfer heat very easily to the incoming air going into the engine. This is a bad thing. Most also suck from under the hood. Again this is bad because your sucking in hot under hood air. Most CAI really help keep the air entering the engine alot cooler than a stock set up plus sucking the air straight from the outside rather than under the hood is a major advantage also.For every 10 degrees you lower your incoming air temp you will gain 1 HP. I measured my intake air temp before putting on my custom CAI and it was reading around 155 on a 80 degree day. With the set up I have now my intake air temps are around 105 on a 80 degree day. That's 4 HP just doing that.May gas mileage has also increased 2 mile per gallon since installing my CAI. This is mainly dew to the fact the engine doesn't have to work as hard to suck in the air so it uses less fuel than it used to.Hope this answers your questions. If you have anymore let me know I'll answer them the best I can. As for draw backs You'll lose your warrenty on your carppy plastic intake because you removed it and if you cut any wires like to your Air Temp Sensor you'll lose your warrenty to it also. BUT YOU WONT LOSE YOUR WARRENTY ON ANY OTHER PART OF THE VEHICLE. I have posted about this before and it's against the law for a dealership to say you have voided your warrenty because of a modification you have done. They can't do this legally. If they do please refer to my post in the Off Topic forum about what to do if your warrenty is denied. You wont have any more problems with your dealership.A CAI is loud. Not exhaust loud but it has a very performance throaty sound to it. I love it personally but some might not.Here is a good before and after performance example. I have a 2001 Kia Spectra auto. Before installing my CAI a new Honda Civic auto would all ways beat me by about 3/4 car length in a guestimated 1/4 mile from a light. After this mod the same Honda Civic I beat a few times by a full car length. It a noticable difference in the (removed) dyno also.
Re: Make your own CAI! (d_m_kolb)
Posted: Mon Jul 29, 2002 2:01 am
by Frosty
I will be definitely looking into a CAI build for myself if I ever get my car. I sold it on the basis of fuel mileage increase to the Mrs. How many db noise increase do you figure it caused? Will my wife freak on me when she hears it? Compared to an open exhaust on a Harley would be a 0, a supercharger a 5 and a Lexus a 10 what do you figure a CAI would rate?Thanks, Ken.
Re: Make your own CAI! (Frosty)
Posted: Mon Jul 29, 2002 2:21 am
by d_m_kolb
quote:I will be definitely looking into a CAI build for myself if I ever get my car. I sold it on the basis of fuel mileage increase to the Mrs. How many db noise increase do you figure it caused? Will my wife freak on me when she hears it? Compared to an open exhaust on a Harley would be a 0, a supercharger a 5 and a Lexus a 10 what do you figure a CAI would rate?Thanks, Ken.When your just regular driving and keeping the RPMs under 3000 you wont really hear any difference. You might notice your throttle response is alittle better and the car seems to accelerate a little better but wont hear it. Ok after 3000 RPM if your not at WOT it wont be bad but if your floored Wide Open Throttle your going to hear it. My wife gets mad at me because I floor the car just to listen to the CAI and the engine wind out because it sounds so cool. Ok back to noise with the windows down I'd say from 1 to 10, 10 being the loudest and 1 being quitest it's a 4. It's not like exhaust but you'll be able to hear and so will the car next to you. With the windows up it'll be more like a 3 1/2. My wife likes the sound. She said it kinda sounds NASCARish. LOL If you want to test the noise for your self just disconnect the suction tube from the Trottle body and start and rev the eng. Get the revs up high so you can hear that but also at a highway RPM to see if you can handle it. That's about what it will sound like but not quit as loud because it will be going through a filter and tubing. It will give you a idea though. Be warned if you do this I think you'll like what you hear.
Re: Make your own CAI! (d_m_kolb)
Posted: Mon Jul 29, 2002 3:19 am
by Frosty
Sounds like big fun to me. Thanks, Ken.
Re: Make your own CAI! (Frosty)
Posted: Tue Oct 08, 2002 10:27 am
by mu_ohio
I know this is an old topic, but does anyone have pics of a Matrix or Vibe with a CAI installed? I'm looking for ones from both top and bottom so that I can get a mental picture of where I have to route mine.
Re: Make your own CAI! (mu_ohio)
Posted: Tue Oct 08, 2002 10:15 pm
by d_m_kolb
Any place you can run the tubing into the front of the wheel well is what you want. I was able to run mine right in front of the driver side wheel well and it sits right in back of a vent in the front of the car. The inlet is away from any heat source and has fresh air. As long as you do this you should have no problems.When I made mine I had no pictures to go off of and only basic info to make it work. It's very easy. The only thing I had to remove when installing my CAI was the battery which went back in after the install. Here are a few pics I have found with a aftermarket CAI installed on a Matrix XR.
Re: Make your own CAI! (Admin II)
Posted: Wed Oct 09, 2002 7:56 am
by savedbyzero
can't use the existing mount. it's molded into airbox. i made bracket for mine, but i'm getting a check engine light. save up the other 150 bucks to get AEM or injen. That's what i'm doing now. i'm a big believer in D-I-Y, but this engine is too dang smart! just my conclusion.
Re: Make your own CAI! (savedbyzero)
Posted: Wed Oct 09, 2002 9:16 pm
by d_m_kolb
There have been a few Matrix guys that have done a custom CAI on there vehicles. The ECM wont know a custom CAI from one you purchased from a store. As long as you reinstall the sensors and make sure they are conected correctly (wiring wise and the MAF sensor isn't installed backwards) you'll have no problems. Plus you just saved yourself $200 to $250!
Re: Make your own CAI! (Admin II)
Posted: Wed Oct 09, 2002 10:16 pm
by NovaResource
What you don't understand is that the mount for the MAF is part of the air box. It can't be removed and used in a home-made CAI unless you cut up your original air box. That's not worth it to me.
Re: Make your own CAI! (Admin II)
Posted: Thu Oct 10, 2002 12:21 am
by NovaResource
I wish or I would have built my own. You could easily cut up the stock box but then you wouldn't have the original to put back if you needed/wanted to. A new factory box from the dealer would cost too much and the Vibe is still too new to find one at a salvage yard. In time they will be easier and cheaper to get.
Re: Make your own CAI! (NovaResource)
Posted: Thu Oct 10, 2002 12:28 am
by d_m_kolb
Is there any way to not cut anything up and still make the custom CAI? It might look goffy but it's then functional.
Re: Make your own CAI! (Admin II)
Posted: Thu Oct 10, 2002 1:17 am
by NovaResource
Possibly. There is an opening to the stock air box where a factory tube connects. Cutting the opening larger and installing a larger diameter tube and routing it to where the Injen intake goes would work, however, you would still have the restrictive box to deal with.
Re: Make your own CAI! (NovaResource)
Posted: Fri Oct 11, 2002 7:31 am
by d_m_kolb
This is just additional info about the stock air intake sensors.The Mass Air Flow sensor (MAF) also has the Inlet Air Temp sensor made into it. It's a 2 in 1 sensor. The reason I know this is because I didn't know the answer to this question so I called a local dealer and they looked this info up for me. There should be 2 other device like sensors in the stock air intake but they aren't sensors. They are purge valves. What they do is recerculate small amounts of exhaust back through the air intake at different times. They can create a suction and suck from the air intake or purge them selfs into the air intake.I figured this info might help out anyone doing a custom CAI on there Vibe or Matrix.
Re: Make your own CAI! (Admin II)
Posted: Sun Oct 13, 2002 12:02 am
by d_m_kolb
Found out some new info. You can remove your MAF sensor without cutting anything on the stock intake. The MAF is held in by screws. You can unscrew it. On your custom CAI piping cut out a hole for the MAF/Inlet Air Temp Sensor (Same sensor) and now install it in the hole. Adjust the MAF sensor hole if it needs to be bigger for a better fit. Now mark your screw holes. Make sure when you drill the holes for the screws, to use a smaller drill bit than the screw your using. Now install the MAF sensor. Make sure the MAF is facing the air flow just like it was on the stock intake. Use a maker and place a on the top of it so you know which way the air flowed through it. If it's installed backwards it will cause a cell to light. Now with the MAF sensor installed you'll probably have a few places that aren't sealed tight with the CAI piping. Use some silicon (High temp perfered) and add it anywhere you see a gap. IF you ever need to install the stock intake the MAF sensor will unscrew and the silicon can be pulled off. This should now work with out cutting any part of your stock intake. Make sure you have holes drilled into the custom CAI piping for the purge valves also. Silicon should easily hold these in place when completed.
Re: Make your own CAI! (Admin II)
Posted: Sun Oct 13, 2002 2:31 am
by NovaResource
Yes, the MAF unscrews out of the top, however, the mount is flat and a CAI tube is round. There is no good wat to seal the MAF without building a mount like Injen did:
Re: Make your own CAI! (NovaResource)
Posted: Sun Oct 13, 2002 3:56 am
by d_m_kolb
I explained this in my last post. The MAF will not sit flsuh with the round CAI Piping. Once you have installed the MAF in the custom CAI piping you will have gaps. Using silicon will fill in these gaps and you should be fine.
Re: Make your own CAI! (Admin II)
Posted: Sun Oct 13, 2002 11:09 am
by NovaResource
You can't just drill a hole in a pipe and screw the sensor in. It's a precision instrument that needs to be centered. Filling the gaps with silicon poor engineering in my opinion.
Re: Make your own CAI! (NovaResource)
Posted: Sun Oct 13, 2002 11:35 am
by d_m_kolb
Is this making sense to anyone else? First off you would have to cut a hold in the custom CAI piping so that the MAF would fit down inside the pipe. Once that's done and it is a good fit you would mark the holes where the screws will be placed. Remove the MAF and drill your screw holes. Now reinstall the MAF in the hole you made for it in the piping and secure it with 2 screws. Now it should be securely fixed to the piping with of course some gaps since the MAF has a flat surface and the piping in round. You would then fill in the gaps with silicon.quote:You can't just drill a hole in a pipe and screw the sensor in. It's a precision instrument that needs to be centered. Filling the gaps with silicon poor engineering in my opinion.You should be able to center the MAF once you have made the hole in the piping for it. You can move the sensor (center it) and mark where you want the screws placed to keep it in the position you feel is best.You said filling the gaps with silicon is poor engineering? This is a custom CAI. Of course it's not going to be as pretty as a INJEN or AEM but it will be funtional and that's what we are going for.Please by all means give other sugestions if you feel silicon isn't good but that's what I have used on my custom CAI and it has been holding my Inlet air temp sensor it for many months now with no problems. I have posted the pics of this above.
Re: Make your own CAI! (NovaResource)
Posted: Sun Nov 10, 2002 9:46 pm
by Flip-Side
Thats what people told the inventors of Duct Tape and GOOP. Improvisation, and functionality are acceptable. Engineers simply refine and perfect according to their own guidelines. I'd like them to tell me that a burst radiator hose shouldn't be fixed with duct tape, or stripped threads patched with GOOP on a cross country trip. I'd rather not pay for a tow truck and overpriced service thank you. Creativity kicks ***!Dig the CAI man!
Re: Make your own CAI! (Flip-Side)
Posted: Sun Nov 10, 2002 10:30 pm
by d_m_kolb
Thanks. I dig it too. Let us know if you do it on the Vibe.
Re: Make your own CAI! (Flip-Side)
Posted: Mon Nov 11, 2002 7:54 am
by NovaResource
quote:Thats what people told the inventors of Duct Tape and GOOP. Improvisation, and functionality are acceptable. Engineers simply refine and perfect according to their own guidelines. I'd like them to tell me that a burst radiator hose shouldn't be fixed with duct tape, or stripped threads patched with GOOP on a cross country trip. I'd rather not pay for a tow truck and overpriced service thank you.Sure, those are great temporary fixes but I'm not about to build a permanent CAI out of duct tape and GOOP.
Re: Make your own CAI! (NovaResource)
Posted: Mon Nov 11, 2002 11:03 am
by Flip-Side
Just because it is jury-rigged, doesn't mean it isn't quality. Check this guy out.
Re: Make your own CAI! (Flip-Side)
Posted: Mon Nov 11, 2002 11:33 am
by d_m_kolb
Hey I didn't duct tape any part of my CAI. No Goop either. Gasket sealer yes goop no. (Gasket sealer used to seal air temp sensor in piping)
Re: Make your own CAI! (Flip-Side)
Posted: Mon Nov 11, 2002 10:20 pm
by NovaResource
LOL! That's good. Does the guy have a webpage with instructions?!