DIY CAI

(or Do-it-yourself Cold Air Intake)

 

If you are here then you probably have heard of the gains that are possible by getting rid of that restrictive stock intake and adding an AEM unit instead. When I first saw the $230 AEM price tag I about fell over. I wondered how anyone could spend that much on some tubing, a filter, some clamps and a sticker. But, if you are a cheap bastard (like me) and have the tools and skill you can make your own. So here is how I made mine.

Before you go any farther. I am not responsible for anything that goes wrong with your car or this installation. Take your time, think things through and use common sense. Perform this modification at your own risk.

 

Materials:

1 - 180º bend 2.5” mandrel bent aluminized steel tubing	JCWhitney	81zx3035n	$23.00
3 – 2” rubber sleeves with clamps (they will stretch)	Lowe’s		$4.00 ea
1 – Conical Air filter	Auto Parts Store		$20.00
1 – AN fitting (for crank case vent)	Auto Parts Store		$2.00
1 – 12” length of rubber hose	Auto Parts Store		<$1.00
2 – small hose clamps	Auto Parts Store		$1.00
1 – Barstock	Lowes		$1.00
1 – can High Temp Paint	Auto Parts Store		<$4.00

                                                                                                                                                                                                Total:    $54.00

Tools:

Screwdriver

Hacksaw

Drill

Welder (optional)

 

  The first step in making the intake is to wash the tubing. Mine was covered in manufacturing oil and filthy

  Remove the stock intake assembly and front bumper

  Lay the pipe in the engine bay to get an idea of how you will cut the tube to best fit your car. I started at the throttle body and worked my way down.

  In the tools list I said the welder was optional. In the places where I’ve welded the pipe you can just use hose clamps. I welded mine to reduce the number of clamps I would need, for a cleaner look and to make the unit more rigid. In the above pic you can see where I welded pipes together. I also ended up welding the two upper pipes (1&2) together later on because it would flex too much and come loose.                

          

 

  Now that you have all the pieces cut out and deburred you need to install the AN fitting. This is a very important step. Without this fitting and the hose installed the car will not run. If you look in the pics you will not see on mine. That is because I installed mine on the backside… don’t ask why. I drilled a hole, used a tap to put threads in the tube, screwed in the AN fitting and sealed it with JB Weld. You don’t want any air leaks.       

 

 

 

 

 

 

 

                                                                                                                                                       

  Next, you need to make a support bracket. I found some barstock at Lowes and welded it to tube #2. The slotted end fits onto the screw that held on the stock air box.                                        

 

 

 

 

 

  Painting. I originally chose Silver 1200º paint. If you use this paint you must bake it in the oven to fully harden and cure it, otherwise; it will rub off and make a mess… once again, don’t ask. I later decided I liked the red 500º paint better anyway.

 

 

 

 

  

 

  Here is the final product in the car.

  Finally, put the bumper back on and go for a drive!

  The first thing I noticed was the sound. The car definitely has a more aggressive growl, especially at higher RPMs. I haven’t dyno tested it yet but it sure feels stronger all the way up until redline.

  Water Ingestion. I live in Florida and I’ve had this setup installed for about a 6 months. I’ve driven through puddles that are 4”-6” deep and hard rainfall. I haven’t had any problems.

 

  For a look at another CAI project check out this link at teamsolcal.com. It’s on a Del Sol but the info is great.

 

 

 

 

 

Update: I welded the two upper pipes together so the system now has only 2 pipes and I painted it red. I also got the sticker from my brother