CAI? Objective complete! - Pontiac G6 Forum
 
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post #1 of 15 (permalink) Old 05-01-2011, 04:15 PM Thread Starter
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CAI? Objective complete!

I could not afford to install a crabs or any other intake kit for that matter. So I decided to set out to fabricate my own.

Requirements.
LOW COST
Function as a CAI
Look Like a CAI
Not Be Hokey

I started by ripping out that massive air box, and stored it along with the brand new filter I bought a few weeks ago.



I attached a intake coupler to the mass airflow sensor. This was a little tuff but not to bad. I attached a 4 in tube and a cone filter. Looks like an intake to me!




I took a few measurements to determine what the rough dimensions of the heat shield would be, and cut a rough mock up out of a box from an 18 pack.



Trim... and Test Fit... Trim... and Test Fit... Trim... and Test Fit...
I think I took this in and out of the car about 20 times.



Once I was happy with the fit. I cut the pattern out of sheet metal.



And again with the Trim... and Test Fit...



I added a few finishing touches...



and here is the final install.



Well I know it's not perfect. but I think I accomplished my goal for now. I will be looking into a front pipe soon though.

All in all this was a fun and challenging project. It took me a several hours to get the heat shield mocked up. and a few more to fab the sheet metal. So I see where buying the kit and the 20 min install time is probably better.

First impressions are.

No CEL, so that's good

It seems to have opened it up quite a bit, as it feels more peppy.

Sounds way healthier. nice little growl when I put my foot in it.

I can't really comment on mileage.. I can't keep my foot out of it. So I'll keep you posted.

I'm not sure what the symptoms of heat soak are, but I see no negative side affects to my mod so far.


So that's that...

Lets hear your comments!
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post #2 of 15 (permalink) Old 05-01-2011, 04:42 PM
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Quote:
Originally Posted by Wisdom View Post
I could not afford to install a crabs or any other intake kit for that matter. So I decided to set out to fabricate my own.

Requirements.
LOW COST
Function as a CAI
Look Like a CAI
Not Be Hokey

I started by ripping out that massive air box, and stored it along with the brand new filter I bought a few weeks ago.



I attached a intake coupler to the mass airflow sensor. This was a little tuff but not to bad. I attached a 4 in tube and a cone filter. Looks like an intake to me!




I took a few measurements to determine what the rough dimensions of the heat shield would be, and cut a rough mock up out of a box from an 18 pack.



Trim... and Test Fit... Trim... and Test Fit... Trim... and Test Fit...
I think I took this in and out of the car about 20 times.



Once I was happy with the fit. I cut the pattern out of sheet metal.



And again with the Trim... and Test Fit...



I added a few finishing touches...



and here is the final install.



Well I know it's not perfect. but I think I accomplished my goal for now. I will be looking into a front pipe soon though.

All in all this was a fun and challenging project. It took me a several hours to get the heat shield mocked up. and a few more to fab the sheet metal. So I see where buying the kit and the 20 min install time is probably better.

First impressions are.

No CEL, so that's good

It seems to have opened it up quite a bit, as it feels more peppy.

Sounds way healthier. nice little growl when I put my foot in it.

I can't really comment on mileage.. I can't keep my foot out of it. So I'll keep you posted.

I'm not sure what the symptoms of heat soak are, but I see no negative side affects to my mod so far.


So that's that...

Lets hear your comments!
It looks pretty Legit.. now make sure you take out the intake resonator.

Exterior-AVS window and sunroof wind reducer, Dual Exhaust, Tinted tails, 35% Tint all around, DDM tuning 8k Highs & Lows.
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post #3 of 15 (permalink) Old 05-01-2011, 04:48 PM Thread Starter
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It's long gone...
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post #4 of 15 (permalink) Old 05-01-2011, 05:24 PM
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Nice. Now you need to paint it. Also, it's a heat shield, not a CAI. Bothered me.

At first I thought that bud light cardboard WAS the heat shield and I almost face palmed until I saw the aluminum.

2006 Pontiac G6 GT

Appearance Mods: AIT front bumper, Black Eagle Eye Halo Projectors with DDM Tuning 5000k HIDs 35w,
GT door decals, painted interior trim, red calipers, de-chromed window trim
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post #5 of 15 (permalink) Old 05-01-2011, 05:52 PM Thread Starter
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haha...

That would be pretty funny if it was just the cardboard.
Well I did make the heat shield, but the project was to install the intake. I guess a true CAI would go into the fender.
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post #6 of 15 (permalink) Old 05-01-2011, 07:12 PM
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It reminds me of something.....cant really put my finger on it.

It's tin?

Cold Air Boxes are classified as CAI's. K&N will even tell you that.

MODS:
Crab Intakes CAB, MPD Ram Air hood, Custom exhaust,
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post #7 of 15 (permalink) Old 05-01-2011, 09:09 PM
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Quote:
Originally Posted by Lampoon View Post
It reminds me of something.....cant really put my finger on it.

It's tin?

Cold Air Boxes are classified as CAI's. K&N will even tell you that.
I guess so.

2006 Pontiac G6 GT

Appearance Mods: AIT front bumper, Black Eagle Eye Halo Projectors with DDM Tuning 5000k HIDs 35w,
GT door decals, painted interior trim, red calipers, de-chromed window trim
Performance Mods: WAMS tune, CRABS, aftermarket sound system

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post #8 of 15 (permalink) Old 05-01-2011, 10:31 PM Thread Starter
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Quote:
Originally Posted by Lampoon View Post
It reminds me of something.....cant really put my finger on it.

It's tin?

Cold Air Boxes are classified as CAI's. K&N will even tell you that.
I told you I was going to try it...

It's not tin. it's galvanized sheet metal. We shall see if it reflects the heat.

any tips on measuring the temperature inside the air box?
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post #9 of 15 (permalink) Old 05-02-2011, 04:26 AM
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I measured AIT's with a Dashhawk when I was testing.

MODS:
Crab Intakes CAB, MPD Ram Air hood, Custom exhaust,
WAMS High Performance Tune and a whole lot more....

My Progession
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post #10 of 15 (permalink) Old 05-02-2011, 05:17 AM
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What material do you use Robert? I'm certainly not an expert but I would think sheet metal wouldn't be overly "heat resistant".

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post #11 of 15 (permalink) Old 05-02-2011, 05:34 AM
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I use

MODS:
Crab Intakes CAB, MPD Ram Air hood, Custom exhaust,
WAMS High Performance Tune and a whole lot more....

My Progession
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post #12 of 15 (permalink) Old 05-02-2011, 09:43 AM
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That looks like a GREAT JOB!!!

I bet if you built them... You could sell them... Probs make good money too. There is little overhead building those and with a protective coating and a catchy name you got yourself a new business!!!!
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post #13 of 15 (permalink) Old 05-02-2011, 12:24 PM
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He used 15-5PH for the heatshield.
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post #14 of 15 (permalink) Old 05-02-2011, 02:43 PM
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I would love to see a how to on this man...definitely looks like a great project for this summer
Edit: rather how or what did you cover the sheet metal with cause I think that's the only thing you didn't explain ha...great job by the way looks great

2006 Pontiac G6 V6 3500L
Crimson Red

Last edited by reverttheclown; 05-02-2011 at 02:56 PM.
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post #15 of 15 (permalink) Old 05-02-2011, 07:00 PM Thread Starter
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A how to? Ok

First the get rid of the gonkulator!
then buy a dealy-O and a thing-a-mabobber.
Next connect the dealy-O and the thing-a-mabobber and connect it where the gonkulator used to be.
Then make a hickamabob.
POOF! Intake... DONE SON!

Just kidding.
I don't think a how to is in order yet. It's not a proven design. I say we wait and see what happens. She is still a work in progress.


Oh Sorry Tupp. I think the niche is saturated. If someone wants one they know where to go.
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