FWD Tech Guides '95-'07 Guides/How-To information for FWD Montes 1995-2007

Mod Guide: Making a CAI box

  #1  
Old 11-22-2007, 10:06 AM
5 Year Member3 Year Member1 Year Member
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Join Date: Aug 2006
Posts: 1,147
Default Making a CAI box

the way that i made my box was i used some 1/8 inch thick plexy glass from menards.

1.I first made the back heat shield that would be closer to the engine and built everything off that. I would cut every thing using a razor blade by scoring both sides of the plexy glass and then just apply pressure to make it snap. (make sure you score it about 5 or 6 times with a good amount of pressure.

2. I used a hole saw for the intake tube to be able to slide into but i made it a
little smaller so i could sand it out and make it fit snug around the tube.

3. then i built the bottom of the heat shield to make the back and tried to make it bump next to my p.c.m.

4. i then made the side wall for it that would be next to the radiator hose

5. i then connected the side to the back and then the back to the bottom and then the side to the bottom using small L brackets with rivets.

6. In order to get the box/ heat shield in i had to take off my cross brace to fit it in.

7. Then i got another L bracket and attached it to the side heat shield and to the cross brace to hold it all in place.

I was then done and this all took me about 2.5 hours.
One problem that i did encounter though is making the hole for the intake tube the plexy glass has a tendency to crack so you should take your time while doing this.

Items:
Plexy glass 1/8 inch think by 24*24 inch
razor blade
hole saw
drill
file
rivets and rivet gun
L brakets
wrench for cross brace
tape messure
straight edge to help with cuts


http://www.cardomain.com/ride/2571140/5
 
  #2  
Old 11-22-2007, 10:22 AM
Join Date: Dec 2005
Location: SpaceCoast, Florida
Posts: 16,095
Default RE: Making a CAI box

Luke
Thanks for the super `pic's and write `up
Now, tell you dad you need more money for `gold, LOL,
I mean `Gas : )
I know the first time I had a CAI on my car, I just couldn't
stop kick'in it down to hear the awesome sounds.
Some of my `friends thought I put a supercharger or
turbo on my ride : )
EnJoy, be safe & have `fun on your B-Day : )
`Space & the Beach `Bum's
 
  #3  
Old 11-28-2007, 05:27 PM
Join Date: Sep 2007
Location:
Posts: 146
Default RE: Making a CAI box

Nice project!

How much did you save with your DIY project?
 
  #4  
Old 11-29-2007, 04:28 AM
RocknSS04's Avatar

Monte Of The Month -- August 2007
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Join Date: Sep 2006
Location: Michigan
Posts: 5,231
Default RE: Making a CAI box

A suggestion for anyone trying to do this yourself, forget the Plexiglas (acrylic) and instead use Lexan or similar (polycarbonate). Costs about twice as much, but it's not brittle like the plexi', and just as easy to work with, and maybe easier because it won't crack.
Try a glass shop for it, and you can probably go to 1/8" instead of the 1/4". It's THAT much stronger.
 
  #5  
Old 11-29-2007, 03:37 PM
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Default RE: Making a CAI box

ORIGINAL: RocknSS04

Try a glass shop for it, and you can probably go to 1/8" instead of the 1/4". It's THAT much stronger.
But wouldn't the 1/4 be better because of the heat that it would be blocking? or would both sizes do the same?

also i just realized that in my original post i said 1/4" but used 1/8"

then i probably saved around $80 doing it my self
 
  #6  
Old 11-29-2007, 06:19 PM
RocknSS04's Avatar

Monte Of The Month -- August 2007
5 Year Member3 Year Member1 Year Member
Join Date: Sep 2006
Location: Michigan
Posts: 5,231
Default RE: Making a CAI box

You saved $80, but you got one probably WAY better than you could buy, or that's at least my opinion of my K&N.
 
  #7  
Old 02-07-2008, 10:05 PM
Join Date: Jan 2008
Location:
Posts: 94
Default RE: Making a CAI box

I made a topic about this not too long ago. I am planning to build my own (not willing to pay $300 for the K&N FIPK) plus I intend to actually improve on their design by making the entire thing a sealed, insulatedsheet metal box with a lexan top so you can see the K&N filter inside. It's pretty much supposed like a WizAired CAI. Here's a link to the thread where I provided more specific design ideas.

https://montecarloforum.com/m_76015/tm.htm

I don't have an aftermarket intake on yet, but I love the suction sound that they make. So if I make a fully sealed cold air box for it then would I be able to hear that suction sound less?
 
  #8  
Old 02-10-2008, 07:24 PM
Join Date: Oct 2006
Location: North Fond du Lac, WI
Posts: 3,986
Default RE: Making a CAI box

Looks a lot better than I expected!! Great job!
 
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