UltraPower Cool Air Intake "Part Two"

[DriVer]

I had a half a mo they say in Jolly Ol' England so I installed the retro fit air box that I received from Brazels'.

The air box is superbly constructed and must be on the order of 3/16" thick and most likely up to 1/4" of an inch thick in some places. The box is rigid. The "Version 2" airbox is closed across the intake side of the box and this adds to the rigidity of the enclosure. The opening on the intake side occupies 40% of the space on the face of the enclosure. It is rectangularly shaped with rounded corners.


UltraPower Large Air Inlet w/ 60% Closed Face

I can easily observe that the front wall of the airbox will present some blockage to rain however the inside of the enclosure isn't scuppered so if water gets inside the box it may pool in the bottom of the airbox. If this does present a problem in time I may have to add some drainage holes in the back of the box. Now adding more holes in an airbox isn't a swell idea but we'll see how all of that works out.


New Version "2" of the UltraPower CAI Airbox

The steps I used to mount the airbox are as follows. The air intake tube to the MAF at this point is loose on the 1st clamp.
<LI> I fit the air box up on the bumper access through the front wheel well.
<LI> I inserted the intake tube into the back of the air box.
<LI> I aligned the air tube by rotating the tube allowing the airbox to sit flat on the bumper. (2 holes provided)
<LI> I drilled 2 holes into the air intake tube's flange through the new air box.
<LI> Using a vise grip I was able to hold the bolt heads inside the air box while tightening the fasteners on the back side. (this tightens the tube to the airbox)
<LI> Tighten the loose clamp on the air tube close to the MAF. (assembly is pretty rigid right now)
<LI> Lie down under front bumper and drill a hole up into the air box.
<LI> Fit and snug up the 1st bolt into the bottom of the air box.
<LI> Drill up a 2nd time, fit a second bolt, apply vise grip to hold inside the air box and tighten.
<LI> Tighten the 1st bolt adjacent to the 2nd in the bottom of the air box.
<LI> Install S&B air filter inside of air box, rotate on the intake tube assuring a good seat, lift filter toward the back of the enclosure and tighten clamp. (filter fits great lip on intake tube assures good sealing surface when the clamp is tight)
<LI> Clean and reinstall the clear Plexiglas top.
<LI> Start the engine and observe.


Ultrapower CAI Airbox V2 Installed On W22

Inspecting the air-tube once I removed the old airbox demonstrated that the tube was clean as a whistle. Not a speck of dust in the tube.

We'll be running North coming Wednesday to attend the Nor'Easters Regional Rally and I'm interested in observing the noise reduction with this effort more than anything. The original airbox buzzed at different speeds so getting the CAI quiet was important.


Air Conditioning Drain Hose


Drain Horse Discharge End - Contains Insert from Stock Drain Tube

[DriVer]

I had a half a mo they say in Jolly Ol' England so I installed the retro fit air box that I received from Brazels'.

The air box is superbly constructed and must be on the order of 3/16" thick and most likely up to 1/4" of an inch thick in some places. The box is rigid. The "Version 2" airbox is closed across the intake side of the box and this adds to the rigidity of the enclosure. The opening on the intake side occupies 40% of the space on the face of the enclosure. It is rectangularly shaped with rounded corners.


UltraPower Large Air Inlet w/ 60% Closed Face

I can easily observe that the front wall of the airbox will present some blockage to rain however the inside of the enclosure isn't scuppered so if water gets inside the box it may pool in the bottom of the airbox. If this does present a problem in time I may have to add some drainage holes in the back of the box. Now adding more holes in an airbox isn't a swell idea but we'll see how all of that works out.


New Version "2" of the UltraPower CAI Airbox

The steps I used to mount the airbox are as follows. The air intake tube to the MAF at this point is loose on the 1st clamp.
<LI> I fit the air box up on the bumper access through the front wheel well.
<LI> I inserted the intake tube into the back of the air box.
<LI> I aligned the air tube by rotating the tube allowing the airbox to sit flat on the bumper. (2 holes provided)
<LI> I drilled 2 holes into the air intake tube's flange through the new air box.
<LI> Using a vise grip I was able to hold the bolt heads inside the air box while tightening the fasteners on the back side. (this tightens the tube to the airbox)
<LI> Tighten the loose clamp on the air tube close to the MAF. (assembly is pretty rigid right now)
<LI> Lie down under front bumper and drill a hole up into the air box.
<LI> Fit and snug up the 1st bolt into the bottom of the air box.
<LI> Drill up a 2nd time, fit a second bolt, apply vise grip to hold inside the air box and tighten.
<LI> Tighten the 1st bolt adjacent to the 2nd in the bottom of the air box.
<LI> Install S&B air filter inside of air box, rotate on the intake tube assuring a good seat, lift filter toward the back of the enclosure and tighten clamp. (filter fits great lip on intake tube assures good sealing surface when the clamp is tight)
<LI> Clean and reinstall the clear Plexiglas top.
<LI> Start the engine and observe.


Ultrapower CAI Airbox V2 Installed On W22

Inspecting the air-tube once I removed the old airbox demonstrated that the tube was clean as a whistle. Not a speck of dust in the tube.

We'll be running North coming Wednesday to attend the Nor'Easters Regional Rally and I'm interested in observing the noise reduction with this effort more than anything. The original airbox buzzed at different speeds so getting the CAI quiet was important.


Air Conditioning Drain Hose


Drain Horse Discharge End - Contains Insert from Stock Drain Tube

[oemtech]

Gee, I guess my orginal design wasn't all that bad.

[DonavonP]

Nice write up DriVer. I'm interested in hearing about the noise level after your trip. And you're opinion of the reduction of water in the filter.

[DriVer]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by oemtech:
Gee, I guess my original design wasn't all that bad. </div></BLOCKQUOTE>I told you no stinkin' screens! Tony Montana

You will notice the cross section in square inches of intake opening is significantly larger than your design.

[DriVer]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by DonavonP:
Nice write up DriVer .... I'm interested in hearing about the noise level ... </div></BLOCKQUOTE>10-4!

["007"]

Mike is bringing me and others the CAI to rally in Tenn I hope they have your upgraded box looks cool. Does the clear plastic window have a rubber gromet around the perimeter of opening, maybe thats what is causing the noise level. Oh by the way are you bringing your tools to the rally.
I can live with some noise just to get rid of that TUBA.
You sure do good work.

[rogueii]

Is Brazel's selling the new Box ? How Much $$ ?

[DriVer]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by "007":
Mike is bringing me and others the CAI to rally in Tenn </div></BLOCKQUOTE>I'll bring mine.

[DriVer]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by rogueii:
Is Brazel's selling the new Box ? How Much $$ ? </div></BLOCKQUOTE>Yes, You're experience may vary!

["007"]

DriVer, so you are willing to bring your tools and help when you said quote" I'll bring mine"

[DriVer]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by "007":
"I'll bring mine" </div></BLOCKQUOTE> Let me clairify that, I'll bring my CAI.

We can talk about it though.

[oemtech]

I will bring my tools....

["007"]

We may never see DOLLY if we keep this up, first training on the and now this. Think we can squeeze it all in.