Blade_Irl

This is a little long, but I think it is usefull, partic to the Euro guys with 1.4's who think theres no hope for our lil engine! I am very confident that this CAI will get me 8-10bhp when complete in CAI form, -and I will know, cos I have dyno results from the way she was standard, and now with just the exhaust system,and will get it done again after this is done.

Finally got round to getn started on making the plastic model of my CAI so I can get it built in Stainless Steel. Got the short-ram(slightly longer than normal ones tho) section mock-up built today,tho a couple of tweaks still to do. Rekn Ill get that built 1st then measure up what I need for the CAI extension once the 1st part is on the car-more accurate that way.

Before the below, I removed the Intake Resonator box - all it does is quieten things down slightly! It comes out very easily, 2 or 3 bolts.

First,I made this hole, its already there on all Civics with horizontal draft/linear throttle bodies. The CAI extension will be exiting the engine into the recess between the bumnper and the stone guard here.:


Then I bought one of these(you have to click this one). A universal K&N Filter good for up to 140bhp. http://www.redbrick.dcu.ie/~blade/mycar/cai/k&n.jpg

Then I got some of this(Its actually truck radiator hosing - v.strong kevlar/rubber type stuff). It will be used to join the intake pipe to the throttle body, and the Short-Ram to the CAI extension:


Then I got some plastic piping, and a couple of connections and made the following model of the short ram:



Still some work to do on the part where it connects to the throttle body, but im gona find out what sort of pre-fabricated bends are available-i.e. long or short, either way from the start of the intake pipe to the highest point of the bend over the Throttle body can be no more than 4" or it wont fit under the bonnet.

Also to be sorted are: a grommet for the Air sensor, and a bung for the oil breather pipe-prob get that welded on. And also a bracket to support the pipe from one of the screws at the side of the peice of the chassis that surrounds the strut top.


Costs so far:
K&N Filter: €55
Small jubilee clips: €5
Rubber hosing&large jubilee clips: €nothing
Plastic piping & connections 2make mockup: €10
Total: €70
I estimate the construction of the Short-Ram Stainless Steel pipe at no more than €50, (rekn the cai extension mite be another €10-20).

Overall estimated total: €130!! (+ my valuable time!)

When the above part is fabricated and on the car, ill make a mockup of the CAI extension that will join to the above pipe with some of the rubber hosing above,and then exit the engine bay into the bumper, leaving the filter to draw lovely cold air from inside the bumper!

Bren

steve_s

You get a 10 for creativity but I think it looks messy.

sparq

Im prettu sure they already make intakes... why didnt you just buy one? Seems like alot of useless work.

rainmanEK

Why buy Somthing When you can Make it?

I think It came out Good, And should work Well!

Eric

splitime

I think technically thats more of a really long short ram, if you want to make it a CAI continue the tube down through the hole and attach the filter down in the bumper area. Currently you have a little draft through that hole, but mainly you are drawing upon air from the engine bay.

illi Adik

Yeah, if you are going to make it that long you might as well just extend it out of the engine bay so it can get nothing but cold air.

gleinz

That's beastacious...keep us posted.

The Destroyer

Why is the diameter piping so small, it looks like 1-1.5"

Evs-One

it looks about 2 inches....but what you guys have still failed to realize, is that the piping is JUST FOR A GUIDE. He's going to follow that setup, and make it out of stainless steel, as he already stated. He;s making it out of plastic so he can figure out the dimensions and have the tubing cut

The Destroyer

OOOOOOOOOOOOHHHH reading is knowledge right.

Timmayeg

im doing this
http://www.teamdelsol.com/home/frameset.htm

Blade_Irl

Thanks man! You wudnt believe how many ppl have just looked at the pics and not read the post and assumed thats the finished article.

It will be 2.5" Stainless Steel(polished I hope).

And I am making a CAI, Im gettin that part made up and gona fit it 1st, then i can measure the CAI extension dimensions more accurately once thats on the car.

Bren

Blade_Irl

Its merely a model so I know what fits where, and what length to make it,a nd where to have a support added etc.

Bren

drkblue_civic

looks like *** but if it works then

silverEH2

whoa

JaeOne3345

if you really wanna do it right. get a y8 manifold first. then make an intake.

Loco Honkey

I'm not because you still have your stock exhaust manifold and exhaust piping. I'm sure it'll do something, but not 8- 10 HP, especially on a 1400. What's the stock HP? 50? So you're expecting a 20% gain from just an intake? I'd say you'll be lucky to see five. But don't let me **** on your parade. Kudos for building your own stuff!

Blade_Irl

Stock my car was 97.6bhp. Tho Honda claim it at only 93bhp.

My car is now 104.9 bhp - it has a Stainless Steel exhaust system from Manifold back with de-cat and bore increased from 1&5/8" to 2".

both those results are prooven on a rolling road dyno, i have the printouts.

My friends '96 1.4 Civic hit 108bhp with just an AEM CAI(the one meant for your DX/CX fits!) and a Thermal R&D backbox. now I dont think the backbox was doing much, hence why I rekn the CAI gave bout 8-10bhp. And mine is a simple design with less bends as im using the hole in the chassis that the AEM CAI for your EX/Si uses.

Its actually a surprisingly powerful motor for a 1.4.

Bren

Blade_Irl

As I said, thats just a model to get the dimensions right., the finished Item wil be polished stainless steel.

Bren

Blade_Irl

Not sure if I mentioned this but it will be 2.5" Stainless steel when i get it built.

Any1 else any advice / suggestions/ criticisms(having properly read my 1st post that is)??

Bren

SOHC_MShue

looks like crap, but if it works then go for it

Evs-One

you're an idiot

isotopesope

can no one read on this board!? the photo is of a protoype to figure out fitment. he's going to fabricate this in steel piping once he has the shape, fitment and routing determined!!! christ on a cracker!!

btw, i think you should have the piping route into that hole so the filter is out of the engine bay. just my .02 cents.

Evs-One

wow...someone else who can read!!!

I do agree with going into the fender well also

hardcorehonda

Don't do that!!!!

You live in a country where it rains 80% of the time.
your filter wil get way to wett and dirty in a short time.

i build a Filterbox on a d15.
It worked good.
here's a pic (not to clear because the hood didn't open anymore after the crash)

(no pic... imagestation troubles)