Homemade Shielded/Insulated CAI
03-05-2012, 09:05 PM
#1
Homemade Shielded/Insulated CAI Plan is similar in concept to the Cold Air Inductions kit but with a couple differences:
1. no nipple in the elbow for the front valve cover breather. I made an error in hose routing for the PCV. This will be corrected tonight.
2. Utilizing a 4x9" AEM Dryflow filter. this thing is HUGE. too big really but for 20 shipped from fleabay i'll make it work.
3. setup with an expansion to a 90mm+ intake/100mm MAF in mind - change out a couple couplers and you're ready to rock.
The airbox will be constructed out of two sheets of 28ga sheet metal with 2 layers of graphite header wrap in between.
first phase was mocking up the huge filter and trying to determine layout of PCM/TCM. I ended up murdering the bottom of the stock airbox so i could maintain the stock mounting tray for the time being. the PCM/TCM look like they'll be inside the new airbox as well to protect from heat & elements.
I used:
4x9" AEM Dryflow filter
3" to 4" molded 45* elbow
(2) 3" to 4" couplers
about 4" of 4" exhaust tubing
the couplers could really stand to be 3.25 or 3.5" if you can find them. I will say all of mine had to be trimmed down if not for stretching them over the MAF then for overall length & fitment. this filter is butted tight up against the headlight bucket and you can barely get it in and out. I trimmed the 45* coupler at an additional angle to allow everything to be positioned where i needed it to be. All 3 to 4 couplers were trimmed down about 1" on the 3" side. These pics are of phase one being complete. THis car is my DD so the airbox templates and mockup will begin wednesday with my days off.
1. no nipple in the elbow for the front valve cover breather. I made an error in hose routing for the PCV. This will be corrected tonight.
2. Utilizing a 4x9" AEM Dryflow filter. this thing is HUGE. too big really but for 20 shipped from fleabay i'll make it work.
3. setup with an expansion to a 90mm+ intake/100mm MAF in mind - change out a couple couplers and you're ready to rock.
The airbox will be constructed out of two sheets of 28ga sheet metal with 2 layers of graphite header wrap in between.
first phase was mocking up the huge filter and trying to determine layout of PCM/TCM. I ended up murdering the bottom of the stock airbox so i could maintain the stock mounting tray for the time being. the PCM/TCM look like they'll be inside the new airbox as well to protect from heat & elements.
I used:
4x9" AEM Dryflow filter
3" to 4" molded 45* elbow
(2) 3" to 4" couplers
about 4" of 4" exhaust tubing
the couplers could really stand to be 3.25 or 3.5" if you can find them. I will say all of mine had to be trimmed down if not for stretching them over the MAF then for overall length & fitment. this filter is butted tight up against the headlight bucket and you can barely get it in and out. I trimmed the 45* coupler at an additional angle to allow everything to be positioned where i needed it to be. All 3 to 4 couplers were trimmed down about 1" on the 3" side. These pics are of phase one being complete. THis car is my DD so the airbox templates and mockup will begin wednesday with my days off.
Last edited by fubar569; 03-06-2012 at 11:29 AM.
03-06-2012, 08:49 PM
#3
pictars. I have the bottom plate almost finished.
im gonna try like hell to seal this as close as i can to the headlight bucket and the fender area. I still have to figure out hat to do about the PCM/TCM. they're going in the airbox too...i just don't know how yet.
im gonna try like hell to seal this as close as i can to the headlight bucket and the fender area. I still have to figure out hat to do about the PCM/TCM. they're going in the airbox too...i just don't know how yet.
03-11-2012, 11:06 PM
#4
Intake work is finished. Lid to come later. This is before the high heat ceramic paint. it tucks TIGHT to the headlight but will still need a gasket for a good seal.
this was not a total drop in affair. It required me to cut off the nipple on the expansion tank and thread it in at a different location. I also had to extend that coolant line.
One side is removable to facilitate installing the ECM/TCM modules inside the new airbox. each are mounted on rubber isolators.
the big benefit to this setup is it is made with 4" in mind. the filter, couplers, etc are all 4"...it adapts down to 3" for the MAF and again at the TB. when i get to do the intake swap and 90mm TB all i do is swap out 2 couplers and drop in a 85mm or larger MAF and rock & roll.
more pics forthcoming
03-12-2012, 07:24 PM
#7
i cut a small hole in the 45* and siliconed the nipple in the elbow. pcv functions as normal
the shield makes a big difference
i also did the IAT relocation mod today with a stock LS1 IAT and pigtail from advance auto. cost was 33 bucks. mounted in the end of the air filter.
the shield makes a big difference
i also did the IAT relocation mod today with a stock LS1 IAT and pigtail from advance auto. cost was 33 bucks. mounted in the end of the air filter.
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03-12-2012, 09:31 PM
#9
To do it with just a stock GM sensor you will need to look up an IAT for a 1998 LS1 camaro (Z28 or SS) and the matching pigtail. any advance auto will have these 2 items and your cost should be about 33 bucks.
You will want to cut and splice into the wires on pins A & B on the MAF connector which on my car were black and tan (PIN A - Low Reference/Ground...PIN B - IAT Signal). the sensor itself doesn't care what wires go where as long as the 2 wires are connected to those 2. cut them with enough slack on the MAF connector side just in case you need to revert back to stock. connect the pigtail to these 2 wires in the harness and you're done. Locate the sensor in a place of your choosing. I put mine in the end of the filter although some say it is best to place it the closest to the TB as you can. really either location is fine for our purposes as the MAIN thing is getting the sensor out of the heatsoaked MAF tube so it reports a much more accurate reading of the incoming air. If you heatshield or heat wrap the entire intake tract to the TB you can almost locate the sensor anywhere.
another premade option is Caspers sells a plug & play harness for this mod. plug MAF connector into harness, plug it into the MAF and it has a wire run for the IAT already there. pretty clean but my option cost 33 bucks as opposed to 50+ for caspers and 99.xx for the vector motorsports HSRK. vector does have a sensor with a much higher speed but to me it is not worth 60 extra bucks. you can upgrade the thermistor in the 98 LS1 IAT with an Omega 44005 for under 20 bucks and you can improve the speed another 30% or so.
You will want to cut and splice into the wires on pins A & B on the MAF connector which on my car were black and tan (PIN A - Low Reference/Ground...PIN B - IAT Signal). the sensor itself doesn't care what wires go where as long as the 2 wires are connected to those 2. cut them with enough slack on the MAF connector side just in case you need to revert back to stock. connect the pigtail to these 2 wires in the harness and you're done. Locate the sensor in a place of your choosing. I put mine in the end of the filter although some say it is best to place it the closest to the TB as you can. really either location is fine for our purposes as the MAIN thing is getting the sensor out of the heatsoaked MAF tube so it reports a much more accurate reading of the incoming air. If you heatshield or heat wrap the entire intake tract to the TB you can almost locate the sensor anywhere.
another premade option is Caspers sells a plug & play harness for this mod. plug MAF connector into harness, plug it into the MAF and it has a wire run for the IAT already there. pretty clean but my option cost 33 bucks as opposed to 50+ for caspers and 99.xx for the vector motorsports HSRK. vector does have a sensor with a much higher speed but to me it is not worth 60 extra bucks. you can upgrade the thermistor in the 98 LS1 IAT with an Omega 44005 for under 20 bucks and you can improve the speed another 30% or so.
03-13-2012, 12:07 PM
#13
When you ask for the 98 Camaro Z28 (or SS) IAT sensor (may also be known as air charge temperature sensor) just mention you need the matching pigtail for this unit.
Part Numbers for sensor:
Delphi: TS10072
ACDelco: 213-243
BWD: WT3036Z
Part Number for Pigtail:
BWD: PT778
I used BWD for both and the results were just fine. I would've preferred the Delphi sensor but my local advance was out of stock so they discounted the BWD down to the price of the Delphi for me (score!)
Part Numbers for sensor:
Delphi: TS10072
ACDelco: 213-243
BWD: WT3036Z
Part Number for Pigtail:
BWD: PT778
I used BWD for both and the results were just fine. I would've preferred the Delphi sensor but my local advance was out of stock so they discounted the BWD down to the price of the Delphi for me (score!)
03-13-2012, 02:57 PM
#15
on my buick park ave with the L67 i was able to get the IAT's down to within 2 degrees at cruise. that's nice.
03-30-2012, 04:45 PM
#16
I have finally had a chance to drive the car with the new intake on it.
IAT's averaged 2* over ambient at cruise with brief dips to as little as .2 over ambient as indicated by the car's external temp reading on the DIC and by the computer's IAT as read directly by Torque. It took anywhere from 4 to 9 miles to reach those conditions at cruise after sitting for about 30min in my driveway in a hot engine bay.
I will further log in town temps after a period of spirited driving to make sure the engine bay gets good and warm then i'll make sure to take some readings at 25 to 35mph and in stop & go...but so far it is EXTREMELY promising.
IAT's averaged 2* over ambient at cruise with brief dips to as little as .2 over ambient as indicated by the car's external temp reading on the DIC and by the computer's IAT as read directly by Torque. It took anywhere from 4 to 9 miles to reach those conditions at cruise after sitting for about 30min in my driveway in a hot engine bay.
I will further log in town temps after a period of spirited driving to make sure the engine bay gets good and warm then i'll make sure to take some readings at 25 to 35mph and in stop & go...but so far it is EXTREMELY promising.
03-30-2012, 05:04 PM
#17
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Personally im a fan of this one....
http://i1171.photobucket.com/albums/...69/airbox2.jpg
another view...
http://i1171.photobucket.com/albums/...69/airbox1.jpg
I also made this one from scratch
http://i1171.photobucket.com/albums/...69/airbox2.jpg
another view...
http://i1171.photobucket.com/albums/...69/airbox1.jpg
I also made this one from scratch
