AF1 CAI Kit "MacGyver Limited Edition" - FordTough.ca - Home of Canadian Ford Truck Enthusiasts
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post #1 of 12 (permalink) Old 04-26-2008, 07:53 PM Thread Starter
 
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AF1 CAI Kit "MacGyver Limited Edition"

Well finally got the mod done, about 99% just need a better tube to go from the box to the hole in the fender but whats there works ok for now just kinda cheesy, just glad you can't see it in the pics.

Well this idea started with going to try a Marine battery box but there were going to be too many clearance issues so my friend who helped me suggested one of those flip top kitchen garbage cans. We searched and found a nice shiny stainless steel one.

We gutted the inside lid mechanisims and took out the internal trash bin.
We cut the top off of the internal bin to keep the flanged end as a seal for the top. We had to cut about 2.5" off the top of the can itself because it was too long. We then cut a 3" hole in the lid to match the diameter of the air filter adapter and the MAF adapter. Using that black gasket goop we made a tight seal on both sides of the lid. In order to make a tight seal on both sides of the internal bin flange we used self-adhesive rubber weather stripping. Next we had to cut a 3" hole in the bottom of the trash can to put in a 3" flange with about a 2" pipe coming out of it to try to adapt it to the hole in the fender but we found there was not enough clearance at the bottom of the bin for good air flow around the filter so we used what I can only describe as a 6" plastic flange that you might use for a roof vent. Anyway we cut the hole in the bottom of the can to 6" then used the roof flange which extended about 2" out from the bottom of the trash can, this gave us enough clearance for good airflow. We used more of the gasket goop and some small 7/32" nuts/bolts to secure it to the trash can. Now we needed to reduce the 6" pipe to fit the 3" hole in the fender. We used a 6" tin stopper from Home Depot and just riveted it to the 6" roof flange. We then cut out a 3" hole for the 3" flange and use more gasket goop and rivets to secure it. Then we had to use some tin dryer flex hose to get it into the hole in the fender but this is just a temp measure. Going to the junkyard next week to get an old stock airbox and use the snorkle tube off of that.

To secure the lid to the rest of the trash can and to make it easy to remove the filter we riveted 2 chest latches, 1 per side. For now the latches are secure with zip ties so they don't pop open. To clean the filter you pop the latches, loosen the hose clamps at the throttle body, disconnect the MAF, temp sensor and that other hose from the intake tube, loosen the bolt on the support bracket,then just ease it out.

Sorry there are no pics of the building of it but my friend was getting a tad pissed at how long it was taking and the mistakes we made in making it so I didnt want to waste time. The following pics are of the finished product. It looks like the lid is not sealed but it is.

Total cost of this mod was more than I expected but that because I made a few mistakes in the making of it. I figure close to $50. Most of that cost was for the trash can. It even came with a 5 year warranty, but I'm pretty sure I voided that in the first 10 min of the build









Whaddya mean I dont pay my bills?? Whydya think I'm broke!!

03 Lariat Crew 4x4 Line-x bedliner, Truxedo Lo-Pro QT Tonneau.
RIP [97 XL 4.2L V6]
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post #2 of 12 (permalink) Old 04-26-2008, 07:56 PM
 
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How small is the filter?

The average K&N filter would fit in there, but you would be loosing some of the filter as the air wouldn't reach due to flow.

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post #3 of 12 (permalink) Old 04-26-2008, 08:06 PM Thread Starter
 
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I'd have to take it apart to measure it but we made sure that no part of the filter is blocked. The filter goes from about the middle of the latch to about 1/'4 before the black part of the can bottom. Thats why we added the extra space at the end to have room for more air to get in. It works fine. I took it for a run down the 401-402 and back and then used my Xcal to check for any codes ie. lean or rich, came back with zip. I keep meaning to ask Tim, where are all the LAC meets held at? Is it the same place or does it change?

If you want to see it in person give me a shout and I can zip over.


Whaddya mean I dont pay my bills?? Whydya think I'm broke!!

03 Lariat Crew 4x4 Line-x bedliner, Truxedo Lo-Pro QT Tonneau.
RIP [97 XL 4.2L V6]
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post #4 of 12 (permalink) Old 04-26-2008, 09:34 PM
 
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That is pretty cool!!!

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stripped,slammed,& cammed!

aka 1LOW03GT
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post #5 of 12 (permalink) Old 04-26-2008, 09:57 PM
 
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Good job! MacGyver would be proud.
I have to ask as I keep seeing it but what does LAC stand for?
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post #6 of 12 (permalink) Old 04-26-2008, 10:10 PM Thread Starter
 
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Quote:
Originally Posted by Lightning Steve View Post
Good job! MacGyver would be proud.
I have to ask as I keep seeing it but what does LAC stand for?
London Auto Club


Whaddya mean I dont pay my bills?? Whydya think I'm broke!!

03 Lariat Crew 4x4 Line-x bedliner, Truxedo Lo-Pro QT Tonneau.
RIP [97 XL 4.2L V6]
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post #7 of 12 (permalink) Old 04-27-2008, 01:38 AM
 
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Nice touch, around here we call that a farmer's job, 80% of trucks around here have some sort of fix\mod like that old or new ...:icon_smile:

Question, is it still considered a CAI if the filter is enclosed? I always thaught CAI meant the filter was exposed....not sure that's why I ask. I won't put an exposed filter on my truck because I drive in dirty\dusty conditions more than anything, I have a fun enough time keeping the drop in K&N clean...lol.


I only drive in the city, to get out of it!!!
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post #8 of 12 (permalink) Old 04-27-2008, 03:07 AM
 
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A true Cold Air Intake (which is what he's made) is designed to draw in air from out side the engine bay. Had a Stang (6 banger) where the filter was inside the fender (between fender and plastic wheel well).
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post #9 of 12 (permalink) Old 04-29-2008, 12:37 AM Thread Starter
 
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I don't know the actual numbers but the butt dyno does notice its quicker to accelerate, better passing and hill climbing power. And I'm getting better mileage. Normally I get about 500Km/tank city but since I put the intake on and filled up I got just over 600Km before I had to fill up again.


Whaddya mean I dont pay my bills?? Whydya think I'm broke!!

03 Lariat Crew 4x4 Line-x bedliner, Truxedo Lo-Pro QT Tonneau.
RIP [97 XL 4.2L V6]
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post #10 of 12 (permalink) Old 04-29-2008, 01:02 AM
 
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