Modified OEM CAI (long explanation)

[slemmer]

After looking at the OEM air intake and seeing how there are only two narrow openings on the fender side, I thought about how I can improve air flow on the factory air box, so I performed the following operation:

 

Looking in from the right side of the fender, after removing the factory airbox, I cut out two openings, one about 4"x4" on the right side facing the turn signals and one 4"x3" on the lower bottom right corner leaving about a 1/2" edge on the outside of the box for continued strength. Also, these cutouts are below the air filter. I then traced out the opening of the bottom cutout onto the air box's metal plate and cut the same sized opening. The theory behind this is that I preserved the OEM look, while opening up two additional surface areas for external cool air to pass through into the box. I didn't put any wire mesh screening yet, but that will be done when I pick some up at the local hardware store.

 

I then removed the molded air intake tube and noticed how GM addressed sounds. I cut off the "cancerous" growth that was hanging on the bottom of the tube near the top of the neck and sealed the 2" opening with plastic and metal tape.

 

Then, with the air intake tube upside down, I noticed that there was another hollow that faced towards the front of the engine. I cut a 45 degree into the air intake and stopped nears the hose clamp rivet and inserted a plastic shim cut to shape of the air space (shaped sorta like a stretched tear drop, but sideways), and then sealed the inserted plasted, thus cutting off the remaining baffle.

 

The result - sonics are normal during city driving and revs under 2,000 rpm. Took the truck on the highway and sped up. Anything over 2,000 rpm, and under heavy load, you will hear a deep growl from up front! Also, with the increased air flow, I believe the enging is breathing much better. Therefore, I was able to reproduce what those aftermarket CAIs are doing.

 

I still have the OEM filter and debating whether changing to a OEM shaped K&N will further improve the performance, sound, or MPG. I will be following my fuel consumption over the next few weeks to see if anything improves.

 

To the untrained eye, everything looks OEM. Total time of mod - about two hours. Probably can do it under an hour, but I spent more time thinking about what I wanted to do once instead of going through two or three attempts.

 

Thoughts or comments?

 

Stephen

'05 CCSB 5.3L

[asilverblazer]

Also, these cutouts are below the air filter.

 

If you are introducing new air from under the filter box, this air will never be filtered due to the location of the factory air filter. I wouldn't due this even if you add wire screen or mesh the amount of dust and dirt you are allowing to enter the engine is going to significantly reduce it's life expectancy. at this point you will need to scrap the factory air filter, and modify the intake tube to accept a cone style air filter. Basically what you have done is taken the lid and filter out of your factory air box the air being pulled in to the engine will take the easiest route, the un-filtered way. Unless I am understanding your description here, this isn't such a great way of trying to solve this problem, as for the baffles for this to work properly the modified tube must be as smooth (on the inside) as possible for the air to move most efficiently.

 

Don't take offense to this, just pointing out some problems you might want to look into.

[slemmer]

I take pics tomorrow - my daughter took the digital away for Easter stuff today. The cutouts were made below the air filter so all intake air is filtered.

[asilverblazer]

For this to work the cut outs must be above the air filter, the intake tube is below it. Thus air coming in bleow the filter won't be filtered.

[slemmer]

Hmmm....I better take a look at what you mentioned. I (thought) the air intake was above the filter. If I'm wrong, then yes, I'll need to replace the box and have another beer to think about another way to solve my quest. It wouldn't be very good if I'm not filtering the air...

[asilverblazer]

I'm gonna feel real dumb if it is above.

[slemmer]

Yeah, and I'm going to be even dumber if it's below! I don't think I'll be having a good sleep tonight...

 

Update -

I'm going to get a good night's sleep ... the air intake to the engine is above the airbox.

 

http://www.imagestation.com/album/pictures...l?id=2107302963

[asilverblazer]

Well seeing that picture clears the air don't it. The reason I was thinking it was below, is because of how close it is to the lid. I kept thinking that it was level with the lid, then I got to thinking about how the air got in, and where it went... I bet your idea will work pretty well then.

[slemmer]

No problems, asilverblaser. After you put that thought in my head, I was worried that I was sucking dust for about 50 miles after taking on to the highways earlier in the day. I'll post my pics later.

[slemmer]

OK, here are the pics of the modified airbox and intake...

 

http://www.imagestation.com/album/pictures...107260788&idx=0

[JAMIEZ71]

I had done something similar on my 1996 and it seemed to help mpg a little. I thought about doing that with my factory box but I put the cai on instead.