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Unread 03-04-2006, 04:48 PM   #1
00xj54
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My Homebrew Intake System

Most people said to KISS it. But I did anything but that. My heatshield is very elaborate. It was pretty much inspired by Dino Saava from JU. This was his for his FIPK. http://www.jeep4.0performance.4mg.com/FIPK.html

Mine is a little more inovative.

I used Rusty's Air Tub and a 6x9 K&N Air Filter. There is nothing to special there. This thread mainly reflected my heat shield/splash guard.

It was a pain in the *** to figure out all the dimensions. It just just fitted pieces of poster board first to get some aproximate sizes. Then I used them a template to cut out my cardboard. (I actaully used the box that Rusty's sent my stuff in)

This was the shape I got. See those black things.....


These are silicone pot pads I bought at wal-mart. There's good up to 675 F so I thought they would be good from insulation in my heat shield.


I covered those pads with a another section of cardboard that fit perfectly over them.

Next, I covered the entire cardboard with Foil Tape.


I put flaps with the foil tape on most the edges to make sure there wasn't going to any spaces between the heat shield and engine compartment when I install it.






This is what it looks like installed....


I had to use a couple extra strips of foil tape to tape it right in the compartment to make sure it was all waterproof in the corners.


Top View


I used the stock bolts plus some new big flat washers to bolt it down. I also used some RTV Sealant on the bolts to make sure it waterproof there.


I am going to make a lid for it too when I get the time. If you are interested in bulding one for yourself let me know. I'll help with some sizes and everything.

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Unread 03-04-2006, 04:50 PM   #2
XJ4oh
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Nice.. Looks alot like Dino's. Only thing I would have done different would be to hit it with some hi-temp paint. Probaly black, but thats just me..
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Unread 03-04-2006, 07:01 PM   #3
FitchVA
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that looks like it took some time! good work
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Unread 03-04-2006, 07:17 PM   #4
XJ-NoDough
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I'm impressed, I just stuffed one of my wheel well liners, after some trimming down, under mine to act as a splash shield, I call it my deep water forging kit. It also helps to funnel the blow-by down into one little area vs. all over my engine compartment.
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Unread 03-04-2006, 07:42 PM   #5
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Looks good. Sorry I wasn't able to get you some pictures of mine in time.
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Unread 03-04-2006, 10:58 PM   #6
00xj54
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Quote:
Originally Posted by FitchVA
that looks like it took some time! good work
Yeah it took sometime. I felt like I was doing a science project for 6th grade.

Quote:
Originally Posted by nick_deno
Looks good. Sorry I wasn't able to get you some pictures of mine in time.
It's cool. It worked out fine.
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Unread 03-05-2006, 12:13 AM   #7
beckXJ
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Quote:
Originally Posted by 00xj54
Yeah it took sometime. I felt like I was doing a science project for 6th grade.



It's cool. It worked out fine.
I wouldn't have used cardboard. I would have used something a little bit more heavy duty. But it still looks WONDERFUL, great fabrication.
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Unread 03-05-2006, 12:37 AM   #8
5point9Limited
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Nice Job Markk! looks great! notice any difference in performance?? I would imagine so. Call me...
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Unread 03-05-2006, 08:23 AM   #9
spitfirees20
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Wow, I was just going to make one of dino's for my xj but this looks great! I am intirested in making one exactly like it, is there any way you could send me all the info you have? measurements etc Thanks!
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Unread 03-05-2006, 10:46 AM   #10
00xj54
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Quote:
Originally Posted by spitfirees20
Wow, I was just going to make one of dino's for my xj but this looks great! I am intirested in making one exactly like it, is there any way you could send me all the info you have? measurements etc Thanks!
Dimensions are in mm. This isn't perfect, so trying do that on spare peice of cardboard first and see if it fits.


Make sure put the flaps on these edges. Just over hang one strip of tape on both sides.


I got the Filter and the Air Tube from Rusty's Offroad,
I got the 2 ply cardboard ffrom that Rusty's shipped me things in
I got the 234 Foil Tape from Home Debot
I got the "pot pads" from Wal-mart

What else do you need to know????
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[B]|15" Canyon Crawlers | 30x9.5 Bridgestone Dueler A/T Revos | [Lifted (2" Teraflex Spacers | 2.5" RE AAL | Edlebrocks IAS)| K&N Homebrew Intake | Flow Master 70 |Clear Corners/Side Markers| Class III Hidden Hitch | C4x4 Fronts Tow Hooks | JKS Discos | Surco Safari Rack | Hella 500s |
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Unread 03-05-2006, 10:47 AM   #11
TheWombaT
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Whats the performance gain?
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Unread 03-05-2006, 10:53 AM   #12
00xj54
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Quote:
Originally Posted by 5point9Limited
Nice Job Markk! looks great! notice any difference in performance?? I would imagine so. Call me...
Quote:
Originally Posted by TheWombaT
Whats the performance gain?
I'd say it's really only a small change right now. That is, until I bore the TB and get a new exhaust system.

But I definatly see the RPMs jumping up faster when I floor it. Esp when I'm already going.
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Unread 03-05-2006, 11:27 AM   #13
TheWombaT
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Is there any place you can get it dyno'd? Like it'd be neat to dyno it now, then mod the TB and exhaust and see what kind of numbers you come up with. I'm interested in a new intake for my 1996 Cherokee but im afraid the "no significant bolt ons" theory for jeeps is true.
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Unread 03-05-2006, 11:35 AM   #14
spitfirees20
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Ah thanks, I'm going to make one as soon as possible
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Unread 03-05-2006, 11:52 AM   #15
00xj54
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Quote:
Originally Posted by spitfirees20
Ah thanks, I'm going to make one as soon as possible
Also make sure you reinforce that triangle peice on the bottom with some extra tape. That's where the bolts are going through
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[I]00' XJ Sport. 4.0 I6.
[B]|15" Canyon Crawlers | 30x9.5 Bridgestone Dueler A/T Revos | [Lifted (2" Teraflex Spacers | 2.5" RE AAL | Edlebrocks IAS)| K&N Homebrew Intake | Flow Master 70 |Clear Corners/Side Markers| Class III Hidden Hitch | C4x4 Fronts Tow Hooks | JKS Discos | Surco Safari Rack | Hella 500s |
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