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Discussion Starter · #1 ·
I have been reading so many posts lately where people are knocking CAI's due to the fact that they bring in warm air from the engine compartment. I decided to try to make one myself with a heat shield that actually works. This is what I came up with today. Remember, I woke up this morning and decided to pull this off.<p>Parts List:<br>Steralite storage tub from Target @ $3.00<br>Spectre 60 degree elbo Intake tube from Autozone @ $10.00<br>3" x 3" Coupling from Sears Hardware @ $6.60<br>3/4" x 7/16" x 10' Rubber foam weatherseal self stick tape from Sears Hardware @ $3.80<br>1 - 1/4" x 42" Air Conditioner weatherstrip from Sears Hardware @ $1.70<br>Small tube of clear silicone @ $2.20<br>PowerAdder cone air filter from AutoZone @ $25.00<p>I did not take pics until the project was completed, so you will have to do your best to visualize the different steps.<br>Step 1:<br>Remove your current air box. Including the top which will require you to unscrew it from the MAF sensor housing.<br>Step 2:<br>Cut the corner of the Steralite container off.<br>Trim the container so that it fits into the opening where the air box once was. You want to leave extra at the top so that it nearly comes into contact with the hood when you shut it. This will allow you to create a seal that keeps out even more of the engine heat.<br>Step 3:<br>Cut a hole in the shield for the turbo's intake hose that has the MAF sensor on it. Use a marker to mark where the two holes on the MAF housing line up with the shield. Drill them out just larger than the bolt that you will use to attach it.<br>Step 4:<br>Cut a hole for the current air intake hose to come through the shield below the turbo's intake hose. This is the hose with the square end. It is a tricky cut since it will not be square with the shield.<br>Step 5:<br>Attach the shield to the bottom of the cavity. I used a self tapping screw with a washer and drilled into a shiny metal thing. Make sure not to hit the small line that is down there. I don't know what it is, but I think that would be bad.<br>Step 6:<br>Slip the MAF housing through the opening that you made in the shield. Bolt it on and put a dab of silicone on the end of the bolts so that the nuts will not work loose. I used the rubber O-ring that came on the original MAF housing to help make the seal even tighter. Probably not necessary.<br>Step 7:<br>Attach the square intake hose to the shield and use a silicone sealant around the edge to keep it in place.<br>Step 8:<br>Use the 3" x 3" coupling to attach the 60 degree elbo to the MAF housing inside the shield.<br>Step 9:<br>Now you can attach the cone filter to the elbo and clamp it down.<br>Step 10:<br>Line either side of the top of the shield with self stick foam tape. Also, run it down either side of the edge next to the fuse box also. This gives you a larger surface to attach the foam strip to.<br>Step 11:<br>Now rub a layer of silicone along the top of the foam tape and attach the foam strip to it. I used the entire 42" strip and sealed off part of the bottom of the box also.<br>Make sure to let everything dry and reattach the MAF sensor cable when you are done.<p>I have not had time to do much driving on it. I will keep you posted on my findings. It does sound pretty wild, though. I did notice that after about 30 minutes of aggressive driving, I lifted the hood and the area within the shield was cool to the touch, while the outside of the shield was very warm. Maybe it works. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0"> <br>I will let you know if my car blows up. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> <br>I almost forgot to mention the best thing.....No stock parts were hurt. You can put the old box back in with no problems.<p>$52.00 and 3.5 hours later, this is what I got:<br><A HREF="http://pg.photos.yahoo.com/ph/the_swish/detail?.dir=1d91&.dnm=a1c2.jpg&.src=ph" TARGET="_blank">http://pg.photos.yahoo.com/ph/...rc=ph</A><p>
 

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Re: S60 Cold Air Intake $52 Mod (Swish)

What is the advantage to this set-up? How is the performance<br>of my car enhanced by this?<br>And for a "home made" set up it looks very professional.
 

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Discussion Starter · #3 ·
Re: S60 Cold Air Intake $52 Mod (TCNJ49)

The purpose of most CAI is to allow air to flow more freely into the engine. A cone filter is typically less restrictive than a drop in. The problem everyone talks about is the fact that the standard CAI will suck in hot air from the engine compartment. This will usually hurt the performance more than it helps. The stock Volvo box is very good, but I thought I could do better. I also really like the sound that an open CAI makes with a turbo. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/smile.gif" BORDER="0"><br>After driving around for a couple of hours tonight, I think I can notice a slight improvement on the upper end. Take-off seems fairly normal, but it appears to have a little extra punch while passing. It also makes a cool whine and then whoosh noise when the turbo kicks in. I will keep you posted and let you know how things go.
 

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Re: S60 Cold Air Intake $52 Mod (Swish)

I just got done doing this mod. I found that putting the silicone on was the most messing part.I don't know how I am going to make the inside of this mod. look nice. I will post a pic tomorrow when it is bright.
 

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Discussion Starter · #5 ·
Re: S60 Cold Air Intake $52 Mod (myVolvoS60T5)

I look forward to seeing your CAI. Attaching the stock intake was the hardest since it is not a very flexible hose. I even tried heating it with a propane torch to bend it. That didn't work. On my next project, I am going to cut off part of the original intake and add a flexible round hose. This will make it much easier to attach it to the new housing. It will look cleaner and will allow for me to create a slighty larger housing for a bigger cone filter.<br>Even better....Anyone got an extra intake pipe for a 2001 S60 T5????? If I have an extra one, I can always revert back to the original when I take my car in for its regular maintenance. It is still under warranty and I don't want to do anything that they could use against me.<br>Does anyone know if adding a CAI (esp. a home made one) could void the certified warranty in any way?
 

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Re: S60 Cold Air Intake $52 Mod (Swish)

Hey there, I noticed that my intake filter came off... I don't know what I need to do. What do you think? <IMG SRC="http://myspace-358.vo.llnwd.net/00609/85/39/609479358_l.jpg" BORDER="0"> <IMG SRC="http://myspace-341.vo.llnwd.net/00609/14/30/609480341_l.jpg" BORDER="0">
 

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Discussion Starter · #7 ·
Re: S60 Cold Air Intake $52 Mod (myVolvoS60T5)

I think that your filter may be too long. You could get the 90 degree, but the straighter the pipe the better. If you take a look at the pics of my shield, you will notice that it is not square with the fuse box. I made the angle of the shield work with the stock turbo intake pipe. I did this so that I could bolt the MAF housing directly to the shield. This helps stabalize the shield and gives me a little more room. I still think that the biggest issue is the size of your filter. In order to acomodate that large of a filter, you will probably have to replace the stock turbo intake pipe with a more flexible style. Remember to keep it as straight as possible. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> Keep it up and let me know if you run across any tips that may help me out with my design.<p><IMG SRC="http://us.a1.yahoofs.com/users/41e28b96z917424a3/1d91/__sr_/a1c2.jpg?phAq2KEBZ7IYxh8_" BORDER="0"><p><IMG SRC="http://us.a1.yahoofs.com/users/41e28b96z917424a3/1d91/__sr_/22f2.jpg?phAq2KEBCH1UBbkF" BORDER="0"><p><IMG SRC="http://us.a1.yahoofs.com/users/41e28b96z917424a3/1d91/__sr_/192e.jpg?phAq2KEBGmeDSeJE" BORDER="0"><p><IMG SRC="http://us.a1.yahoofs.com/users/41e28b96z917424a3/1d91/__sr_/8011.jpg?phAq2KEBuJ4D3N79" BORDER="0"><p><i>Modified by Swish at 10:56 PM 3-29-2006</i><BR><BR>
<i>Modified by Swish at 11:01 PM 3-29-2006</i>
 

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Discussion Starter · #8 ·
Re: S60 Cold Air Intake $52 Mod (Swish)

How do you get pics to work????<br>Do they have to be on a current site, or can they be uploaded to this server???<br> <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/confused.gif" BORDER="0">
 

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Re: S60 Cold Air Intake $52 Mod (Swish)

well so i have got a NA 2001 and i would like to know whether this eurosport branded intake similar to your homemade ones will increase or decrease power....also i wondered if it helped to also get an evolve hood grille that would be left open for cool air to flow under the hood...let me remind you this is not a turbo engine...<br> <br><A HREF="http://photobucket.com" TARGET="_blank"><IMG SRC="http://i29.photobucket.com/albums/c265/glfgmoney/VLE-160-201-T1.jpg" BORDER="0"></A>
 

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Re: S60 Cold Air Intake $52 Mod (glfgmoney)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>glfgmoney</b> »</i></TD></TR><TR><TD CLASS="quote">well so i have got a NA 2001 and i would like to know whether this eurosport branded intake similar to your homemade ones will increase or decrease power....also i wondered if it helped to also get an evolve hood grille that would be left open for cool air to flow under the hood...let me remind you this is not a turbo engine...<br> <br><A HREF="http://photobucket.com" TARGET="_blank"><IMG SRC="http://i29.photobucket.com/albums/c265/glfgmoney/VLE-160-201-T1.jpg" BORDER="0"></A></TD></TR></TABLE><p>This is the exact setup that I have on my car. It's actually the BSR Optiflow intake rebranded. I dont know how much power it gave me, probably not much, but I love being able to hear the intake and the turbo. On a NA car, you might get like 1-3 hp. Unfortunatly you wont get much with power adders like us turbo guys. The evolve grill would probably help though, if you made sure that it is directly above the filter, and you seal it off to the rest of the engine. You might get a bit of a ram air effect.
 

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Re: S60 Cold Air Intake $52 Mod (Swish)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>Swish</b> »</i></TD></TR><TR><TD CLASS="quote">$52.00 and 3.5 hours later, this is what I got:<br><A HREF="http://pg.photos.yahoo.com/ph/the_swish/detail?.dir=1d91&.dnm=a1c2.jpg&.src=ph" TARGET="_blank">http://pg.photos.yahoo.com/ph/...rc=ph</A></TD></TR></TABLE><p>A+ for effort (and aesthetics)! I am tempted to install an aftermarket CAI, but the 2005 T5 stock air box seems to do a pretty decent job as is. I did replace the stock filter with a BMC though...
 

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Re: S60 Cold Air Intake $52 Mod (darylkaiser30)

yo, the owner of eurosport tuning guaranteed me 9 horsepower gain with that air intake. hes a pretty reputable guy, so id take his word for it. they have some sweet products
 

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Re: S60 Cold Air Intake $52 Mod (liquidforce1887)

yes it will, i tested 8 hp at dyno, btw the EST design is the same as BSR. Same Shield, filter, i got mine from EST and it was the BSR symbol on the shield. Also the turbo spool sounds amazing
 
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