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Discussion Starter · #1 ·
thanks to all the others for the ideas, this is my attempt at a CAI. Just a conduit from lowes hardware. painted it black and cut 2 holes for installation. It's a 2.5" pipe, very smooth inside for easy flow. from the front of the car, you can really hear it sucking the air. it also gives the engine a more aggressive tone. only took 2 hours to complete. <br> [<A HREF="http://s2.supload.com/free/DSC00794.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00794.JPG" BORDER="0"></A><br><A HREF="http://s2.supload.com/free/DSC00799.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00799.JPG" BORDER="0"></A><br>][/I<A HREF="http://s2.supload.com/free/DSC00800-20060317213101.jpg/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00800-20060317213101.jpg" BORDER="0"></A><br><A HREF="http://s2.supload.com/free/DSC00802-20060317213107.jpg/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00802-20060317213107.jpg" BORDER="0"></A><br> [<A HREF="http://s2.supload.com/free/DSC00803.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00803.JPG" BORDER="0"></A><br><A HREF="http://s2.supload.com/free/DSC00805.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00805.JPG" BORDER="0"></A><br>][/IMG]
 

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Re: another CAI option, only $10 (jlemly)

VERY NICE!!! <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <p>I'm wondering why you didn't use the keyhole for access? Was it due to the curvature of the pipe?<p>Now if someone can custome mold a snorkel like that and use the keyhole, BUTTAH!!!
 

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Re: another CAI option, only $10 (jlemly)

I love how simple and clean your design is, many a copy-cat will follow this one I'm sure (including me). Well done <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <p>From all the other CAI threads we know that no water will get in through a CAI like this due to submurging it. However, water mist <I>could</I> get in especially because of how smooth your CAI tube it.<p>It might be worth adding something to cause just a little a bit turbulence, just enough to slow the air speed enough so the water 'falls' out before heading up the tube. vLGrok seems to have good knowldge of this from his Navy days per this thread:<br><A HREF="http://forums.swedespeed.com/zerothread?id=55091" TARGET="_blank">http://forums.swedespeed.com/zerothread?id=55091</A><br>(sending vLGrok a quick IM now to ask him to chime in)<p>Nonetheless, I REALLY like your design and you did a nice clean job on the installation.<p>LTA<p>
 

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Discussion Starter · #4 ·
Re: another CAI option, only $10 (mike_c70)

i couldn't use the keyhole because the pipe is solid, and it touches the intercooler piping, so it can't come any farther up.
 

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Re: another CAI option, only $10 (jlemly)

I have to get some stuff at Lowe's this weekend and I'm adding one of these to the list for a rainy day project.<p>Would love to see your install sometime since we are local!<p>-Ben
 

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Re: another CAI option, only $10 (jlemly)

Yeah, so when are we getting together to put this on my car? <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> Nice work!
 

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Re: another CAI option, only $10 (jlemly)

has anyone ever tried to form PVC conduit like that with heat? it seems like it might take only a little bit of tweaking to allow that conduit to snake around the intercooler pipe, match up with the keyhole, and be more centered and lower in the fog lamp grill. <p>fantastic idea. i like the KISS aspect.
 

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Re: (adamrs80)

jlemly - <p>Very cool idea!<p><TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>adamrs80</b> »</i></TD></TR><TR><TD CLASS="quote">Looks like the cleanest DIY setup so far</TD></TR></TABLE><p>I think my new one is clean... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/smile.gif" BORDER="0"> <p><A HREF="http://forums.swedespeed.com/zerothread?id=55492" TARGET="_blank">http://forums.swedespeed.com/zerothread?id=55492</A>
 

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Re: another CAI option, only $10 (jlemly)

i just got back from Lowes. i tried some forming of this conduit with a heat gun. it worked like a charm. <BR><BR>
<i>Modified by jasondew at 5:54 PM 3-19-2006</i>
 

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Re: another CAI option, only $10 (R Salesman)

anytime Lee, i was telling Holly that we should have you and the new bride over for dinner sometime, i guess we could do some work at the same time.Also, if you guys have a house yet, don't forget i own a flooring store.
 

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Re: another CAI option, only $10 (jlemly)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>jlemly</b> »</i></TD></TR><TR><TD CLASS="quote">anytime Lee, i was telling Holly that we should have you and the new bride over for dinner sometime, i guess we could do some work at the same time.Also, if you guys have a house yet, don't forget i own a flooring store.</TD></TR></TABLE><p>Actually, we're in the process of trying to purchase a 1940's home in NoDa. It's been completely renovated, except that the hardwood floors need refinishing. Do you guys do that stuff (I'd like to have them done prior to moving in, if it's not too expensive).<p>By the way, I think dinner with the four of us (and your little ones) would be awesome! I think our wives would get along great . . . and while they're doing that, we can figure out ways to make our cars faster!!! lol
 

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Re: another CAI option, only $10 (jlemly)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>jlemly</b> »</i></TD></TR><TR><TD CLASS="quote">i couldn't use the keyhole because the pipe is solid, and it touches the intercooler piping, so it can't come any farther up.</TD></TR></TABLE><p>This looks really nice, the only tiny drawback I see is that you took a corner off the keyhole:<p><IMG SRC="http://s2.supload.com/./files/default/DSC00802-20060317213107.jpg" BORDER="0"><p>The keyhole is part of the "snow valve". You'll notice the keyhole is designed to actually block off a small portion of the air filter cylinder. What is designed to happen is if the main air intake ingests enough snow (or dust), it can clog the air filter temporarily. The keyhole ensures that a small surface of the filter remains open, and the flapper will open to supply air when that occurs.<p>Because of the cut into the keyhole, it is possible that snow/dust could competely envelop the filter. This isn't too likely, but it's something to keep in mind. If you could cut in without touching the forward wall of the keyhole, that might be a tiny bit preferable. This would make it an even better approach than using the existing snow valve as a port!<p>Tom.
 

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Re: another CAI option, only $10 (jlemly)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>jlemly</b> »</i></TD></TR><TR><TD CLASS="quote">..., this is my attempt at a CAI. Just a conduit from lowes hardware. painted it black and cut 2 holes for installation.</TD></TR></TABLE><p>That's sweeter than Yoohoo. <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <p>I would re-do mine like that if it's possible to get an elbow (maybe silicone?) or form the conduit to mate to the port in the bottom.<p>
 

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Did you form that bend yourself or did it come bent? If you did form it did you just use a heat gun? What did you use to cut the hole in the box behind the foglamp?
 

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Re: another CAI option, only $10 (jasondew)

i just finished with my install. i'm amazed how clean and easy this setup is. it took no more than one hour to complete. i decided not to try to mold the tube around everything. it fits quite well without modification. there's no real advantage to using the keyhole/snow valve area and it will just add bends to the tube.
 

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Discussion Starter · #19 ·
Re: another CAI option, only $10 (R Salesman)

Lee,when do you plan to move in, we do sand and finish, but our guy is booked atleast 3 weeks right now, so if that fits your timetable, call me soon. I'll definitely hook you up, but you gotta help me out when that softloader gets in. Give me a call sometime this week.
 

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Re: another CAI option, only $10 (jlemly)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>jlemly</b> »</i></TD></TR><TR><TD CLASS="quote">thanks to all the others for the ideas, this is my attempt at a CAI. Just a conduit from lowes hardware. painted it black and cut 2 holes for installation. It's a 2.5" pipe, very smooth inside for easy flow. from the front of the car, you can really hear it sucking the air. it also gives the engine a more aggressive tone. only took 2 hours to complete. <br> [<A HREF="http://s2.supload.com/free/DSC00794.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00794.JPG" BORDER="0"></A><br><A HREF="http://s2.supload.com/free/DSC00799.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00799.JPG" BORDER="0"></A><br>][/I<A HREF="http://s2.supload.com/free/DSC00800-20060317213101.jpg/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00800-20060317213101.jpg" BORDER="0"></A><br><A HREF="http://s2.supload.com/free/DSC00802-20060317213107.jpg/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00802-20060317213107.jpg" BORDER="0"></A><br> [<A HREF="http://s2.supload.com/free/DSC00803.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00803.JPG" BORDER="0"></A><br><A HREF="http://s2.supload.com/free/DSC00805.JPG/view/" TARGET="_blank"><IMG SRC="http://s2.supload.com/thumbs/default/DSC00805.JPG" BORDER="0"></A><br>][/IMG] </TD></TR></TABLE><p>Can this conduit take the heat of an engine in the middle of the Summer? Will it melt? Are you using a particular grade of PVC?
 
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