Cheap DIY intake air temp/flow mods **complete**

[golfyste]

Ok so I found that my k&n cone filter was knackered! So I purchased a new jetex filter and I was thinking while I was a it I might as well try a few free mods 

I decided I was going I heat wrap the Induction pipe, create a heat shield to go behind the bumper, encasing the air filter an stop water from comin up from beneath and also run a cold air feed to it.

So I stated with wrapping the induction pipe, before any of you complain how ugly it is  I don't really mind as I'm the I only one who ever goes under there and don't mind if it serves a purpouse 

So heres how the engine bay looked to begin with....
 

I then removed the cai...


I then marked where I had to wrap from...


I then Started wrapping...


An then I laid a piece of rope near the end, wrapped over it then got the end attached it on the rope and pulled it though to save from using any cable ties 





Ok this is the bit you will hate 

I then Put on some reflective aluminium tape, then put another later of wrap at tape at the top as the bottom part has to squeeze between the battery and Wing....




I also did the same with the part that connector cai with the maf..


And it done....



I know it's ugly but i dont care 

[golfyste]

Ok so this is my k&n filter with a big hole down one side 



So I order the new jetex filter...



I then got under the car and made myself a template for the heatshield ...



I also decided where I was going to run my cold air feed and found the best place was from behind the slam panel behind the grill.
I saw there was a couple of holes but with a normal cold air feed being round I would actually get much air going in so decided I would make a rectangle to round to act as a funnel for the air   

So I did some drawings a made a practice one out of paper...


I then set at making my heatshield...I stated by cutting out the template from sheet aluminium
And I then tidied it up and bent it all appropriately ....



Until it was done 


I then set about making my rectangle to round ...
Marked it all out....



I then cut it out, tidied it up and bent it all round ....





Was I got it all bent round I pop riveted it an it was done 




Got a cold air feed coming shortly so will hopefully get it all fitted over the weekend   

[Wazzzer]

Nice bit of DIY mate

[Nino]

Looking very good mate, alot of thought gone into it

EDIT: I take it you heat wrapped the pipe to prevent the pip absorbing heat from the engine bay?

[golfyste]

Cheers 

Yeah nino just like wrapping a manifold which keeps the heat in, wrapping a cai keeps the heat out which i i decided was a good idea when one day after driving home from work I felt the cai and it was scolding hot 

[Scott D]

precision DIY skills there 

[golfyste]

precision DIY skills there 

Cheers dude 

[golfyste]

Ok so my cold air feed didnt come yesterday so i could fit that and the rectangle to round so i just fit the new filter and heat shield and will drill a hole in the heat shield later.

comparison of the filters.....



new jetex filter is a little bigger but much cleaner 

new filter fitted....


next i slotted the heat shield up into position which went very easily and fitted very nicely 





It held in place quite solid without any rattling/movement so fastening it into position was pretty easy 

i just used some self tappers in the back and then drilled into the bottom part of the front valence and cut and drilled a small piece of 90degrees aluminium and again used some self tappers 





very happy with the fitment, now just gotta install the cold air feed 

[golfyste]

Also forgot to mention that I have already cut out my front grill to allow more airflow  ....

[golfyste]

Ok so been busy this afternoon 

The cold air feed arrived yesterday 


Then placed about with the placement of the pipe until I was about happy 


I then lined in the square to round to where I wanted it and drilled it ...


And attached it with a bolt,washer, nyloc nut and repair washer...


I then marked on my heat shield where I was slotting the cold air feed and removed it to cut ad file it and this is how the air feed hung...


I then attached the air feed to the square to round using te heat reflective tape...



I then sloted the heat shield back in place and pushed the metal end piece for the cold air feed through te filter side of the hole and attached the pipe locking it in place 


Overall I'm very happy with these mods which cost me a total of £13!   
And I can actually feel a small difference with the combination of new filter, heat shield, wrapped cai and cold air feed