My Homebrew Intake System

00xj54 · 03-04-2006, 05:48 PM

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.

XJ4oh · 03-04-2006, 05:50 PM

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..

**FitchVA** · 03-04-2006, 08:01 PM

that looks like it took some time!

good work

XJ-NoDough · 03-04-2006, 08:17 PM

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.

nick_deno · 03-04-2006, 08:42 PM

Looks good. Sorry I wasn't able to get you some pictures of mine in time.

00xj54 · 03-04-2006, 11:58 PM

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.

beckXJ · 03-05-2006, 01:13 AM

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.

5point9Limited · 03-05-2006, 01:37 AM

Nice Job Markk! looks great! notice any difference in performance?? I would imagine so. Call me...

spitfirees20 · 03-05-2006, 09:23 AM

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!

00xj54 · 03-05-2006, 11:46 AM

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????

TheWombaT · 03-05-2006, 11:47 AM

Whats the performance gain?

00xj54 · 03-05-2006, 11:53 AM

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.

TheWombaT · 03-05-2006, 12:27 PM

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.

spitfirees20 · 03-05-2006, 12:35 PM

Ah thanks, I'm going to make one as soon as possible

00xj54 · 03-05-2006, 12:52 PM

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

03-04-2006, 08:17 PM	#4
XJ-NoDough Registered User Join Date: Nov 2003 Location: Four corners--Eugene, Oregon Posts: 1,688 Profile Gallery Classifieds My Jeeps	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. __________________ [SIZE=2][B][COLOR=Blue][B]My DD '89 XJ Limited 204,XXX miles Leather, Loaded[/B][/COLOR] [COLOR=Red][B]4L Selec-trac[/B][/COLOR] [COLOR=White][B]Automatic[/B][/COLOR] [COLOR=Red][B]3"-4.5"ish Homebrew lift[/B][/COLOR] [COLOR=White][B]16x8 MB Motoring Rockers[/B][/COLOR] [COLOR=Red][B]265/75R16(31[SIZE="1"]ish[/SIZE]"X10.4") Goodyear Wrangler M/TRs[/B][/COLOR] [COLOR=White][B]Trimmed w/ Bushwackers[/B][/COLOR] [COLOR=Red][B]Stock 3:55 gears[/B][/COLOR][/B][/SIZE] [B][COLOR=White]sans big audio[/COLOR][/B] [B][COLOR=Red]Homebrew intake w/cone filter[/COLOR][/B] "Some people are like a slinky... Not really good for anything, but you still can't help but smile when you see one tumble down the stairs." :my dad

03-04-2006, 08:42 PM	#5
nick_deno Registered User Join Date: Aug 2005 Location: Wichita, KS Posts: 126 Profile Gallery Classifieds My Jeeps	Looks good. Sorry I wasn't able to get you some pictures of mine in time. __________________ '93 Cherokee Country 4.0L HO: 158k, 235/75/R15 Sport King AT's, K&N Filter w/ custom tube, '01 Intake Manifold, Banks Torque Tube Header, Hella 550 Fog Lights, JVC CD Player [url]http://www.cardomain.com/ride/2188725[/url]

03-05-2006, 11:47 AM	#11
TheWombaT Registered User Join Date: Oct 2004 Location: NJ Posts: 292 Profile Gallery Classifieds My Jeeps	Whats the performance gain? __________________ -2001 Cherokee Sport 4.0 - auto - 80,000m -1996 Cherokee Sport 4.0 - manual - 160,000m

03-05-2006, 12:27 PM	#13
TheWombaT Registered User Join Date: Oct 2004 Location: NJ Posts: 292 Profile Gallery Classifieds My Jeeps	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. __________________ -2001 Cherokee Sport 4.0 - auto - 80,000m -1996 Cherokee Sport 4.0 - manual - 160,000m

03-05-2006, 09:23 AM	#9
spitfirees20 Registered User Join Date: Oct 2005 Posts: 387 Profile Gallery Classifieds My Jeeps	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!

03-05-2006, 12:35 PM	#14
spitfirees20 Registered User Join Date: Oct 2005 Posts: 387 Profile Gallery Classifieds My Jeeps	Ah thanks, I'm going to make one as soon as possible