Headers/Intake/Exhaust Custom Exhaust? New Headers? Need Opinions on Intakes? Discuss making your ride breathe better here.

6th Gen ('00-'05): Gutted Air Box

  #1  
Old 07-30-2014, 04:02 PM
GTHSS's Avatar
Monte Of The Month -- March 2016
5 Year Member
3 Year Member1 Year Member
Thread Starter
Join Date: Feb 2014
Location: Chase City, VA
Posts: 1,965
Default Gutted Air Box

I gutted my air box this weekend in an attempt to build my own cold air intake. Since the stock air box pulls air from behind the head light I thought that by gutting it and insulating it I could save a dollar or two.

So how I started was by removing the brace above the air box and then removing air box. Once I had it out and into 3 pieces I saw that the middle section was where I need to start. Using a small rotary tool with a cutoff wheel I carefully cut all unneeded material away. The third pic will show what I removed beside what is left of the middle section. I used a good pocket knife and a file to de-burr the edges.

Once cleaned and ready for reassembly I added a new K&N filter and replaced the box.

Next step will be to find the right spray on insulation to spray inside the box to keep it cool. I also am going to make a cone style filter adapter to put inside when I insulate it. I think you can get a little better flow from a cone style.

I had to ask myself if I really accomplished much doing this. Well, It took me two hours and several broken cutoff wheels. However I can feel a better throttle response and feul mileage is up from 29 to 31 mpg. The MagnaFlow exhaust is talking a little louder now also. Most of that could be the filter alone though. What do y'all think?
 
Attached Thumbnails Gutted Air Box-img_20140727_170614_439.jpg   Gutted Air Box-img_20140727_153422_875.jpg   Gutted Air Box-img_20140727_170919_018.jpg   Gutted Air Box-img_20140727_170714_594.jpg  

Last edited by GTHSS; 07-30-2014 at 04:07 PM.
  #2  
Old 07-30-2014, 04:19 PM
The_Maniac's Avatar

Monte Of The Month -- December 2011
Monte Of The Month -- September 2014
5 Year Member
3 Year Member1 Year Member
iTrader: (2)
Join Date: Apr 2010
Location: Mentor, Ohio
Posts: 10,911
Default

Nice write up and pics!

If you look at a place like Home Depot, they sell an insulation like what is used in a couple cold air intakes (looks like chrome bubble wrap). Could get that and attach it to your gutted box.
 
  #3  
Old 07-30-2014, 07:25 PM
GTHSS's Avatar
Monte Of The Month -- March 2016
5 Year Member
3 Year Member1 Year Member
Thread Starter
Join Date: Feb 2014
Location: Chase City, VA
Posts: 1,965
Default

Good idea. I might try that.
 
  #4  
Old 08-02-2014, 05:31 PM
GTHSS's Avatar
Monte Of The Month -- March 2016
5 Year Member
3 Year Member1 Year Member
Thread Starter
Join Date: Feb 2014
Location: Chase City, VA
Posts: 1,965
Default Custom Cold Air Intake

Originally Posted by The_Maniac View Post
Nice write up and pics!

If you look at a place like Home Depot, they sell an insulation like what is used in a couple cold air intakes (looks like chrome bubble wrap). Could get that and attach it to your gutted box.
Hey Jason, do you know what department Home Depot would have that style of insulation in?

I have a sheet of 16 gauge diamond plate aluminum in my shop. After i insulate this intake and and fabricate the cone filter adapter, I am thinking about using my final dimensions to build a cold air intake out of the diamond plate. I can't decide if the brightness of diamond plate will be overkill.
 

Last edited by GTHSS; 08-02-2014 at 05:35 PM.
  #5  
Old 08-02-2014, 06:02 PM
The_Maniac's Avatar

Monte Of The Month -- December 2011
Monte Of The Month -- September 2014
5 Year Member
3 Year Member1 Year Member
iTrader: (2)
Join Date: Apr 2010
Location: Mentor, Ohio
Posts: 10,911
Default

I've always seen it in the isle with the normal house insulation. I believe this is the stuff (or something like it):
Reflectix 16 in. x 25 ft. Staple Tab Insulation-ST16025 at The Home Depot

I know what I've seen would be plenty to insulate an air box and was not expensive.
 
  #6  
Old 08-02-2014, 06:24 PM
GTHSS's Avatar
Monte Of The Month -- March 2016
5 Year Member
3 Year Member1 Year Member
Thread Starter
Join Date: Feb 2014
Location: Chase City, VA
Posts: 1,965
Default

Thanks! Great info.
 
  #7  
Old 08-02-2014, 07:38 PM
ZIPPY02's Avatar
Monte Of The Month -- May 2012
Monte Of The Year 2012
Monte Of The Month -- February 2017
10 Year Member
5 Year Member3 Year Member1 Year Member
Join Date: Jan 2008
Location: Mountains of Utah
Posts: 4,653
Default

Nice mod, I don't understand why others have not done this mod. Seems perfectly sensible, totally seals off the air intake from the hot engine bay temps. Just not blingy as the nice CAI systems.

Think you will find the insulation at the back of the store in the lumber section with all the rigid insulation. Usually in racks against the exterior wall, with all the 4x8 full size sheets and the smaller cut up segments.
 
  #8  
Old 08-02-2014, 08:35 PM
GTHSS's Avatar
Monte Of The Month -- March 2016
5 Year Member
3 Year Member1 Year Member
Thread Starter
Join Date: Feb 2014
Location: Chase City, VA
Posts: 1,965
Default

Thanks Zippy. I like that red Monte. Nice car!
 
  #9  
Old 08-03-2014, 12:21 AM
Join Date: Apr 2014
Location: Marion, IL
Posts: 46
Default

I actually hadn't thought of this.. This seems like a great alternative to a CAI(Wizaird/ZZP/CAI)
 
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
dgm
PRIVATE For Sale/Trade Classifieds
0
04-05-2014 11:08 PM
black04monteSS
Headers/Intake/Exhaust
4
04-03-2008 09:17 PM
HaRvArDaLe
Headers/Intake/Exhaust
10
04-05-2007 11:26 AM
big green dog
Headers/Intake/Exhaust
26
12-09-2006 03:45 PM
bangbg
Headers/Intake/Exhaust
7
06-23-2006 05:01 PM


Thread Tools
Search this Thread
Quick Reply: 6th Gen ('00-'05): Gutted Air Box


Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.