Fiberglass Custom Cai

[USMC850T]

Ok so my bro is helping me to fabricate a custom CAI. We went to work this saturday morning fitting and shaping our mold.

The box itself will be semi sealed. It will sit behind the left front airdam hole. My idea is to have the front and bottom sealed to prevent splashing and any hydrolic lock which could happen should I hit a puddle. The top and rear section will be completely open and exposed. When I say sealed, I mean it losely, as it will really only be obstructed to prevent splashing. There will be about 1" clearance between the cone filter and the CAI box on the bottom and front. More than enough to allow air in, but hopefully keep out the water.

jacked up and ready to go

testing for space - this is under the front left portion of the bumber (my skid guard is off)

plenty of room

bro starting to sketch template on foam based on my plan and the space available

rough shape of the CAI "airbox"

sanding that stuff down to make it smooth

belt sander in my butt

hot stuff!! smooth as ice

cut in half, ready to epoxy

epoxy begins

Basically after I sand the epoxy super smooth, we resin the mold to make our 2 halves. From there, the CAI box will be shaped and cut into its final form. Should be another day or two before I have a finished product to show for our work. It should provide the all the performance of a CAI, with the sound of a filter on stick.

[Volvoson]

Looking good so far man :tup:

[mikie]

Looking forward seeing the final result... good job so far tho

[exexpat]

when I saw "Cai" in the title I thought the Chinese word for "vegetable"

Nice fabbing!

[Oreo931]

thats really impressive, i like it...keeep postin pics, real interesting man....gj

[BtownVolvo]

While you're there, you might as well relocate those horns

Keep it up...you have my attention!

[Deuss]

how are you planing on routing a pipe to that region of the car? I absolutly looked at every possible way to run a pipe there and there is no way unless you remove the battery completly and drill some holes in metal on S70

[the underlørd]

how are you planing on routing a pipe to that region of the car? I absolutly looked at every possible way to run a pipe there and there is no way unless you remove the battery completly and drill some holes in metal on S70

yah, i'd be pretty tough..

this is a picture of a S60R airbox modded by TME.

they run the stock airbox, supplemented by air tubes routed from the bumper that feed the airbox from underneath.

[USMC850T]

From the MAF, 45 degrees dogleg left, about 1.5 feet, 90 degrees down, Fin.

There is a hole to drop it down which will work fine. I plan on having a new battery tray / bracket machined for the turn.

[ViperVettte]

when I saw "Cai" in the title I thought the Chinese word for "vegetable"

Nice fabbing!

Wait a second... so your telling me my chinese friend who's last name is Cai. His last name means Vegetable? THATS CRAZY MAN! Or maybe its Kai... all I know is we call him Cai/Kai.

yah, i'd be pretty tough..

this is a picture of a S60R airbox modded by TME.

they run the stock airbox, supplemented by air tubes routed from the bumper that feed the airbox from underneath.

That be looking interesting. Much easier then turning the batery and having a pipe fabbed up. You would have to make sure to do smooth tubes though, accordian tubes would be FTL.

OH YEA! And by the way man, good luck with the install I can't wait to see how it turns out! The only thing that stops me from doing a mod like this is the fear of the h2o... the .

[BtownVolvo]

You would have to make sure to do smooth tubes though, accordian tubes would be FTL.

Get pipes that twist and make the air swirl...it's like 20 extra HP!!!

EDIT: Now that i think about it, if you had the accordian tubes and air was moving fast enough through it, it'd make that cool noise :lol:

[Geevs]

they run the stock airbox, supplemented by air tubes routed from the bumper that feed the airbox from underneath.

Someone mentioned about using the NA airbox with the twin air inlet on a turbo engine. While it's a nice idea that twice the amount of air would be coming in, I wondered if air coming in one of the inlets would actually leak out of the other inlet due to difference in air pressure at the inlets. Anyone with air flow dynamics verify this?

[pwebb]

Someone mentioned about using the NA airbox with the twin air inlet on a turbo engine. While it's a nice idea that twice the amount of air would be coming in, I wondered if air coming in one of the inlets would actually leak out of the other inlet due to difference in air pressure at the inlets. Anyone with air flow dynamics verify this?

I would imagine that the air being sucked into the intake would be enough to keep things flowing smoothly in the right direction.

[ViperVettte]

with the design cold air intake, the air isn't going to be forced in, it is going to be sucked in. So there won't be an excess of air, there will be just the proper amount, provided that the hoses have enough flow. If there is not a flow, there turbine will have to work harder to get the air... resulting in HP loses.

edit-

hmm... if the turbo isn't sucking enough though, it could cause a vacum effect... where the air displaced by the leading edge of the CAI comes back around and disrupts airflow. I would need to think WAYYY to hard about this one, and I'm at work... this isn't the right place to be thinking.\

edit2- go with the first one... Don't worry about the second one.

[USMC850T]

The piping diameter will be 2.75 ID, actually a little bigger, so if anything the MAF is the bottleneck in the system. Unfortunately, it's gonna be accordian until I have a better solution .