The Official Buick Air-Intake Write-Up As Performed By Ryan *disclaimer - don't mind or judge the mud - haven't cleaned the engine bay since the last club run*
1) Parts list...
Air box from an early '90s Buick LeSabre/Century/etc
3" to 2" pipe converter, rubber, straight (available from Home Depot for $6: SKU #687-979)
Screwdriver, socket set, dremel/sanding device
Various around-the-house items
2) Remove TJ airbox. This will be done by first removing the cap of the unit, removing the air filter, and then removing the 3 bolts (I believe socket size 8) that connect it to the fender flare. Keep an eye out, as there are nuts on the other side of the bolts that will fall on the ground. Might be helpful to just grab them before they fall and get lost. I sprayed mine with PB earlier this week to make the whole removal process a little easier. Once you've got the bolts removed, unscrew the pipe clamp that connects the intake hose to the air box. At this point, you can remove the stock box entirely.
3) At this point, you can remove the hose that runs across the engine bay. There is another pipe clamp above the throttle body that will need to be loosened, and the hose that goes into the valve cover. Pretty simple rubber hose to just pull off. Then the whole pipe can be removed.
4) The next step is trimming and fitting all of the pieces together. I used my dremel with a sanding attachment to widen up the hose ends of the adapter, as well as grind down the tubing that goes across the engine bay. I also cut off the tabs and raised plastic portions of the Buick box so that the adapter would fit over it smoothly. The smell of melting rubber sucks. Also- wear eye protection... I got a piece of molten rubber flung at my eye and it sucked. This whole process is a trial and error to see what fits. When you've got everything fitted, crank down the pipe clamps to make everything secure.
5) Once you've got everything tightened down and cleaned up (no need to have rubber bits sucked into the engine) you can fit it back over the throttle body and re-attach the hoses. I had trimmed about 3" off of the engine-spanning intake hose in order to bring the Buick box further center and avoid the support beams that span the engine bay. The official Jeep-Forum write up shows a metal bracket that the guy built in order to support the passenger side of the new intake. Unfortunately the bolt he used was pretttty tight for me, and I wasn't going to bust a knuckle with it since the fenders will be off soon giving me plenty of opportunity to screw with that stuff. I ziptied the intake opening to the support beam thing, and it is extremely secure. I also pulled the intake angle hose off of the stock box and fit it into the Buick box just to give the hose a little upwards angle. Should function well, and I will eventually mold the two together with some form of high-temp flame. In the meantime, it's not going anywhere.
At this point it's also worth replacing the air filter since the junk yard one probably hasn't been touched in a decade. I didn't know exactly what year my box was, so I brought the old filter to AutoZone (you should have seen the sales kid's reaction when I told him I didn't know what year or model it was for.... as if people can't color outside the f*****g lines....) and there's now an image below with a model number so I will never have that problem again. Also note the color difference in the old vs. new filters!
So that's pretty much it. Below are a few shots of the engine bay, before and after. For the $35 it cost to do this, I'm pretty happy. Eventually I'll build that bracket. Good news is that the Jeep sat in the driveway idling for about 20 minutes and seemed happy temperature wise and everything. I put my ear next to the air intake and it was happily breathing fresh air. Hopefully this success continues on.
And then, at 7:05 PM, the UPS man arrived. Honking his horn as he approached the house to find me standing at the end of the driveway awaiting his arrival. It's always great when they share your enthusiasm for arriving parts. Even asked what they were and what they were doing on the Jeep! Then the neighbor walking by commenting on the "MADE IN USA" sticker and made a comment about how he wanted nothing less for my Jeep.
The whole world sung in harmony as I cut the box open.
Everything looks really good Ryan. As soon as I get a job I think I might do that Buick airbox swap. Just for the fact that I would never have to remove the tiny brace bar again to replace my air filter would make my life that much easier. Also, it opens up the engine bay for more equipment like an air compressor.
As for those fenders, they look really nice. I can't wait to see them on your Jeep!
Hey man just came across your build, havent had a chance to go through the entire thing but skimmed several pages back and its lookin good.
Im in CT so not that far, keep me in mind for that run
You went with the 3" flare correct?
Def looking forward to seeing yours because I cant decide between the 3" tnts or the 4" alum genrights. Any idea how much those weigh?
Hey man! Glad you made it over. Enjoy the read if you get the time to go through it. (It's also indexed on page 1/post 1 if you want to skip around).
I'll be sure to keep you in mind for OFR. It's going to be a very small group.
They are in fact the 3" flare. I looked at the Gen-Rights, but their appearance never settled with me. That and the fact that for $650 you've still got to hack up the stock fenders. I ended up getting the TnTs for just over 700 DELIVERED ($100 less than normal) through Jason at Jeepin' Outfitters. Couldn't have asked for a better deal.
UPS says the box weighed 63lbs, although I don't think that's entirely accurate. I'll weigh them this afternoon and let you know.
Yeah the TNTs are very nice for sure especially having the entire inner fender all pre-manufactured where as genright offers an inner fender but for an extra $200. My biggest hurdle before I decide is do I want the weight savings of aluminum that Genright offers for more $$$ or for a better price get a very similar product that weighs alittle more.
If you can weigh those fenders and wouldnt mind throwing a stock fender on the scale when you get those off thatd be awesome!
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This morning I headed out into the world to purchase seam sealer, self etching primer, bondo/putty, acetone, and a few other expendables. I drove right by AutoZone and went to Advance as I really rather prefer them, and one of the sales guys drives a stock JK so I figure the more I park the TJ next to his stocker, the more likely he is to join North Shore Jeeps and get that baby built. Advance didn't have enough primer, so I bought Bondo and acetone. Then reluctantly headed to AutoZone to get primer and seam sealer (which Advance also didn't have!). In AutoZone, the guys kept commenting on the "sick Jeep outside". At the cash register I thanked them for the comments, and one kid asked if it had 8 inches of lift. I told him 3" in the rear (thanks 8.8 axle) and 4.5" up front. AutoZone didn't have seam sealer either.
Went home, and got to work! I've never done a thing with Bondo before so it was a learn-as-I-go kind of thing. Before I got to Bonding, I sanded and acetoned the fenders down. Mid-sand on the right fender, my hand slid down the inner fender wrong, and it sliced about 3mm deep into the corner of my hand, separating about an inch of skin from the rest of my body. Blood literally started pouring out of me, staining the front brickwork, the front porch, and the hardwood in the kitchen. After staring at the greasy bloody hand mess for a few minutes, debating whether or not to cut the skin flap off, I washed it put on some bacatracin and wrapped my hand in electrical tape (remember: I'm a show business guy for a living, we use tape to fix any issues, and I always have a roll of E-tape around). Back to work for me!
At this point I started playing with the putty. My goal was to go around the seam between the fender flare and the tubing, as well as the overlap between the flare and the top of the fender. It took me about 45 minutes to do both fenders, at which point I waited an hour for them to cure. Then I got to sanding! I put a glove on my right hand Michael Jackson style to keep the bondo dust from infecting the e-tape-wrapped wound. Sanding bondo sucks. After finishing that I added some more in small sections to try and even things out. Honestly, I'm accepting a "90%" job on these because I think paint will do a great job at hiding small defects, and I'm not going for show-room quality. Every seam is bondo'd on the outside, and they are pretty smooth considering I've never done it before.
After the touch-up areas cured, I sanded them down again. The hand-over-the-bondo test went well and things were smooth. I'll still have a few days to change my mind and touch some things up again since the paint won't be here till Wednesday (according to a phone call to JEGS today to ask where the kcuf my paint is since I ordered a week ago). Between now and then I am also awaiting the delivery of my "Eastwood Products Seam Sealer" which seems to be god's gift to earth as far as automotive seam sealers go, and the reviews online about it attest to.
Hand is doing better. Thankfully my folks are both in medicine, so they had some Novocaine in the cabinets. Hand is re-bandaged and still wrapped in e-tape . It was insanely challenging to work today due to my right hand being my dominant. Anyway, total consumed beverages: 5 cans of coke, 7 cans of seltzer, and a 32oz Gatorade. I was insanely thirsty working in the blistering heat. Not much to do tomorrow, maybe hit the beach. Fun info about the turn signal situation might be posted due to my boredom tomorrow.
Thank you for reading this boring post, and now please enjoy some boring body-work photos, a FIRST for the Jeep build thread!