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Discussion Starter · #1 ·
I am using my OEM Mustang GT Air Cannister as a homebrew Jeep CAI. The following pictures detail the components. I had to take a break from Jeep restoration the past two days to build a "tea cup" prop for my daughter's high school choral show.:( Anyway, I've based my build from the thread here that the guy used an Apollo CAI going thru the firewall into the cowl area. I will insert the rubber "horn" of the Stang unit thru the firewall. The inside diameter is about 3 1/2" which is more than adequate for air flow. More pics to follow when the install is complete. I would think this part would be easy to come by since it is usually the 1st bolt on performance item in the Mustang world.



This part below was $19.99 at Oreillys and is expandable/bendable. It answered any question/concern I had.



The stock air housing trimmed down to retain the PCV...



The rough unit awaiting installation

 

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what year mustangs use that housing?

I've been cutting down winstar/explorer and escort boxes.. looks like they use about the same element.
 

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Discussion Starter · #5 ·
what year mustangs use that housing?

I've been cutting down winstar/explorer and escort boxes.. looks like they use about the same element.
Mine is an '04. That model year is basically the same from 99-04.
 

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I had both a '94 & '96 Mustang and the '94/'95 style looks like it would make for an awkward looking modification. The Mass Air Flow sensor was mounted inside the airbox for the '94/'95 cars. There is a protrusion on the side of the air box would it look ugly. The '96+ cars have the MAF sensor external to the airbox.

See below:
'94/'95


'96+
 

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Discussion Starter · #11 · (Edited)
The '96 Cobra shown there is the identical setup as my '04. That should be great news for availability. Not too many Stangs out there still have that original air can. Hopefully those guys saved them like me. As for the Mass Air Flow sensor, when unbolted and out of the way, the flexible hose I got from Oreilly's inserts from the inside and fits the hole very snug.

Weather permitting, I should be finished tonight. I drilled my hole through the firewall last night between rain showers but it is 3 1/8" and I need maybe another 1/8th on top/bottom. The rubber "horn" is very flexible but is not completely round. That part doesn't matter so much but the hole is just too small.
 

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Discussion Starter · #12 ·
Complete

I have completed the modifications and installed the new homebrew CAI. I recommend using a 3 1/2" holesaw. I had to grind the bejesus out of the firewall since I used the 3 1/8" saw (what I had laying around). Because the "horn" is contoured and becomes larger as it approaches the filter, the larger the firewall hole, the closer the housing is to the firewall. That, by the way, is preferred to keep from interfering with the dipstick or oil fill. I still may tweak it some but I am very pleased.

 

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Discussion Starter · #13 ·
Also of note - I trimmed the expandable tubing by about 1/3 of it's length.
 

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How's the horn fitting into the hole? Anything to keep it in there where it won't slide out or rattle?

I like this setup and might just steal it. However I'd look into taking a 3" LED light grommit and stuffing the horn into it.

I really am impressed.
 

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Discussion Starter · #15 · (Edited)
The horn is rubber, stiff, and moderately flexible. You just cram it into the hole until it stops and its "in" for good. You really have to yank on it to get it out! I have not even permanently mounted the housing yet.

One word of advice: I removed the 3 factory attachment points. The housing is strong enough so that you can drill a hole in order to attach some sort of bracket if needed.
 

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Discussion Starter · #17 ·
I'll take some more pics tomorrow. Right now it's not mounted to anything. The rubber horn is really the best part of this thing. Keep in mind that I am not "running" just yet. I'm still a few weeks away on my restore which explains why I'm not in a big hurry. You'll notice in the picture that there is no radiator or battery installed. No need for them to be in my way just yet.

Anyway, I plan on coming in from the firewall with a simple strap of some sort that will cradle the housing. I pulled the horn from inside the cowl until it is SUPER snug and it is pretty solid. This housing is not as heavy as it looks. While I do plan to support it in some manner, the end of the horn is belled out so it will never come out of the cowl unless you make your firewall hole larger.

Like I said, I'll snap some more pics soon and we can all tweak this thing together. BTW, I tossed the old Fram Air Hog (K&N type) filter I ran back in 04 and replaced it with an OEM style Wix filter for $19.
 

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Discussion Starter · #19 ·
More pics...

Here are the promised/requested additional pictures.

View from the cowl:


Drivers side cowl:


Passenger side - side view:


Driver's side - side view:


And finally...laying on a creeper under the motor looking up the firewall:
 

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Discussion Starter · #20 ·
Bracket

I think when its all said and done, I will use a bracket similar to the one used in the Buick Airbox write-up. I'll get to that in the next couple of weeks. In the meantime, be my guest to improve upon my simple design!
 
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