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3D Printer to the rescue / AFE CAI


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Posted

Well I ordered an AFE intake for my 2017 6.2L Denali. When it arrived i realized they had shipped the wrong one its for the 2009-2013 trucks.

We went back and forth for a couple weeks trying to find a solution as it was bought on eBay, shipped across border, etc.

 

It ended in them offering to refund me the total cost minus shipping. I agreed.

 

(Figured Id sell it locally and make that $ back)

 

In the meantime I picked up a K&N system for my truck locally so there was no confusion (also the only thing I could find local). I didn't love the K&N setup to be honest. It was loud that's for sure but the open box, using the hood, etc ... I don't know I just don't love it.

 

So I went back to my AFE setup and decided to see what wouldn't fit and what did fit to see if maybe I could make it work.

 

Incompatible Differences:

1) MAF sensor port doesn't work at all with 2017.

2) missing one breather port for the crank case

3) boot that goes onto the throttle body is the wrong size (throttle body side)

4) throttle body on the 09-13 had a slightly different angle but not a huge deal.

 

Went to the hardware store picked up a brass barb fitting, drilled the proper size hole, heat up the fitting & thread into PVC tube = #2 solved

 

Boot from K&N system fixed 3&4.

 

This is the 14-17 MAF port that I needed.

91bf79dc77fbfa7e5be164faaa277b52.jpg

 

And this is the 09-14 MAF port on the kit that they shipped accidentally.

80cc0dd12a4e30912b652deba52f1ea6.jpg

 

Went into my office took about an 20 mins in my design software and a few revisions later I ended up with this. 81191a6245ac644f4bb889844683a306.jpg

 

Dropped that into Simplify3D and made a sample out of ABS.

932e571d04600c4da5d52979cdaad1cf.jpg

 

Trimmed the opening a little, then used some closed cell PVC weatherstripping and some stainless gear I had laying around and strapped her in, perfect fit!

5b382949d32c7c4266383752263e2e06.jpg

 

 

Hooked everything back up, double checked all connections, attached the negative battery cable, fired her up.

11cc50fdef275081e8818e9695ba9886.jpg

 

Runs fantastic (seems a little stronger in the pulls than the K&N but that may all be in my head. Still sounds great but a little more tame / luxurious / refined than the K&N due to the closed box design I think.

 

 

Let me know what you guys think. Love it / hate it / anywhere in the middle.

 

Cheers,

BDC

 

 

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Posted

Love it for the shear fact of the creativity in creating a solution to the problem! Well done!

 

 

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Posted

Thanks guys !! Yeah I was a little pissed at first then I remembered I own a 3D printer and I'm not half bad with the design software ha ha ha

 

Edit: and it ended up being pretty cheap ;) lol

 

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Posted

Thanks guys !! Yeah I was a little pissed at first then I remembered I own a 3D printer and I'm not half bad with the design software ha ha ha

 

Edit: and it ended up being pretty cheap ;) lol

 

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That's really, really cool! I'm a total nerd and love tech innovation like this. What 3d printer amd software are you using?

 

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Posted

That's really, really cool! I'm a total nerd and love tech innovation like this. What 3d printer amd software are you using?

 

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Slicing with S3D , designing with solid works, Lulzbot Taz 5.5 (it's a 5 upgraded to a 6 minus the auto level as I don't want it lol)

 

 

Thanks man !! 3D printers make everything possible pretty much !!

 

I'm pretty excited to put some Km's / miles on it and see how it does!

 

 

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Posted

Slicing with S3D , designing with solid works, Lulzbot Taz 5.5 (it's a 5 upgraded to a 6 minus the auto level as I don't want it lol)

 

 

Thanks man !! 3D printers make everything possible pretty much !!

 

I'm pretty excited to put some Km's / miles on it and see how it does!

 

 

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If you can print an AR lower that bracket will do great lol.

 

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Posted

We don't have guys like you guys up here in Canada but I just looked up 3D printed AR lower .. pretty cool !!!

 

Yeah I'm pretty sure it will be good! I printed it out of ABS, but if I have any issues with it I'll print it in nylon next.

 

 

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Posted

I love to see problem solving. Looks great! Maybe you could go ahead and print me a supercharger

 

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Posted

How big of a 3D printer is it? How long did it take to run?

 

 

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