Made A New Cai Box, What You Think.

[WogsRus]

Well so i was sitting on the net, going over all the CAI designs, ones you can buy and so forth. I remebered that a member of the forum had some templates. SO got those and went to work.

My dad and I started in the morning on boxing day, figured we would take it easy, well 4 hours later, and a six pack of beer, and HAY PRESTO, here is the finished result.

The box case is made out of a product called ALUCOBOND, it's a 1mm ally, with 3mm PVC, and 1 mm ally again. You can buy a thicker ones if required. The inside is lined wiht a THERMOFOAM, it's a 15mm thinck high density foam with silver foil, excellent R values, to miniminse heat transfer. I noticed a 6deg C after introducing the foam.

The air is introduced through a 2'5" pipe from the front of the bar and blows straigh into the box.

SO far the results are great, the car is a lot more constant, if you stand in trafic, the heat lag is gone. The air is nice and cool, and the car is a lot more responsive. Fuel ecconomy is up, and the pod noise is reduced to a more acceptable level.

Only down side, on a cold morning, the dam thing hits R&R so dam quick, as the air is so dense, and the box together with the FMIC, really increase the air flow, hence R&R.

I have the templates available, if people are interested, but i modified mine as i went allong, i found that each car is different. I have done this to my friends R33 4door, with an APEXI filter, and we had to extend the main box body and make a different cover top.

I did mine by making the side first and then making up a pattern to fit for the top cover. The side of the box is held in place by two brackets riveted to the side of the box, and bolted to the car using the stock airbox mounting holes. The top is slid inot place under the front panel, and then bolted through the top, into some brass L-brackets. I then finished the alluminium by brushing it with fine still wool. I did have it polished, but it was VERY hard to keep semi clean. Total cost, ALUCABOND, free i got offcuts, Thermofoam $36 per meter, and all the other bits and peices i already had, so that is DAM Cheep.

Tell us what you think.

Edited January 3, 2007 by WogsRus

[tridentt150v]

Looks good, I want some offcuts?

[WogsRus]

i went to my local supplier, and got some, but unless your in tassie, i recon no go. LOL. unless you want to pay for shipping. LOL.

[NYTSKY]

Ive got an alloy one in mine very similar in design to yours but the alloy also gets pretty hot.Where can i get that thermofoam stuff?

[WogsRus]

well i got mine from the local FOAM LAND supplier.

[Gazee]

Thats some good work dude! looks real neat.. i've seen some real hack jobs with these CAI's but your one looks A1...

[sewid]

Ive got an alloy one in mine very similar in design to yours but the alloy also gets pretty hot.Where can i get that thermofoam stuff?

Clark rubber sell that foam stuff.

[sly-747]

That's mint!

I'm going too attempt too make one for my s2 r33 4door!!

Hope it's not too difficult <_<!

[WogsRus]

nah not to dificult at all, veary easy material to work with.

[Munkyb0y]

looks shmick.

I've been meaning to make one, but just waiting to get my hands on a snorkel before i size it all up.

WogsRus, you should consider selling them on here. I'm sure there'd be alot of interest, especially if your prices arent over-inflated like alot of these boxes are.

[r33gts-t s2]

looks really good im impressed especially with the performance, so not too hard to make one i might have a crack at it when i have a day off.

[WogsRus]

Like i said most of the materials for me were of cuts, and there is plenty more to get. The only problem is that each box is really individual, if you want to do it corecctly. I made sure that there was no leaks or anything, the box fitted well. Depending on each car's setup, the pod hole may be in a different spot and so forth.

I am happy to farward on the design templates as were give to me, i can't take credit for those. I simply improved the design a little, and made it more functional.

BUT i suppose if you had to get materials yourself it would range from $50 if you get some scraps and stuff or about $100 if you did it all brand new, but for $100 worth of materials you can get 5 boxes cut.

Edited January 4, 2007 by WogsRus

[shnaped_second]

It took you 4 hrs to drink a 6 pack? lol looks good anyway...

[WogsRus]

yeah i'm a slow drinker. LOL. Well i did also do some work, or didn't you notice. LOL.

[WogsRus]

Here is teh templates and some instructions as i recived them from the original maker. I do not take credit for these.

MY design is slightly different, in that i made brackets up to hold the side part of the box, and some brackets to screw the top down into.

Like i said i made mine as i went along, but the template is a good base to start with.

If you need any more info, PM me and i'll try and help, and provide some more pics.

cai_zip.zip

Pics.zip

CAI_Template_Inst.txt

[ydawak]

Here is teh templates and some instructions as i recived them from the original maker. I do not take credit for these.

MY design is slightly different, in that i made brackets up to hold the side part of the box, and some brackets to screw the top down into.

Like i said i made mine as i went along, but the template is a good base to start with.

If you need any more info, PM me and i'll try and help, and provide some more pics.

Hey all i am in the process of making one of these for my s1 4 door. The only thing where something can differ is dependant on what type or airpod you use. I have an apexi and wog has a hks one. the hks filter sits off a pipe that you can go around where as the apexi bolts straight to the aiflow meter, so its a bit more tricky to get attached

[corza]

Looks awesome, were the holes in the chassis necessary? did you have any other snorkeling techniques? or was that the reason for the holes.

[WogsRus]

I used the old hole form the stock IC, you can see it in one of the pics. There is a 2.5" pvc pipe that runs form there to the front bar, and picks up cold air form the front of the car.

You could easily use a stock snorkel and plum that inot the side of the box at the top, but i didn't have one.

If you are looking at the pics of the white car, the orignal template pics, he made a hole in the front fender to duct in air. I didn't do this as i already had a hole.

BEST thing if you have a stock snorkel, use that to supply the cold air into the box.

EDIT: I can't spell at ALLLLLL

Edited January 4, 2007 by WogsRus

[corza]

Ah yeah spot on mate, looks brilliant, I think you would go well for selling them :-) its tops

[Gazee]

Thanks for the template dude!