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Air Intake Progress - June 17, 2008

Since I now had all of the major parts to relocate the intake, I started making the intake pipe.

1. I roughly mocked up the 2.5-inch elbow pipe I purchased to see how much to cut off one end in order to fit the elbow to the throttle body correctly. I made the first cut and then mocked it up again to see where to cut the bend.
2. The pipe must be twisted about halfway through the bend to get it to go under the upper radiator hose properly. The picture shows the elbow marked with where to make the cut.
   
3. I cut the pipe and mocked up the two pieces in the engine bay.
   
4. Seeing that the piece going under the upper radiator hose was too long to fit the MAF sensor, MAF sensor adapter, and filter in the battery tray area, I marked and cut a few inches off that pipe.
   
5. The piece that connects to the throttle body was also a bit too long, so I took about an inch off of that pipe.
   
6. With that cut completed, I test-fitted all of the intake parts. Everything looked good, so I marked how the two pieces of the pipe should be twisted relative to each other in order for the intake to fit properly.
   
   
7. I then started working on modifying the MAF sensor adapter provided with the SR20DET A'PEXi Power Intake kit. The adapter has a pipe coming out of its side that I won't be needing. I cut the pipe off with a hacksaw, then cut out a small circle from 1/16-inch aluminum sheet metal to fill the hole. I pressed in the aluminum piece and then covered the hole from both sides with Liquid Metal Filler.
   
   

That was all I had time for today. I went to AutoZone and got a large package of JB Weld to use for joining the two pieces of the intake pipe. I also took a couple more pictures of the garage.