ehofmann
11-03-2017, 10:26 PM
Before I begin, I feel like we need to name this intake. Something german, preferably inappropriate, but still sounding cool.
I started to design my intake as a replica of the Roc-Euro setup, however found that the rear pipe would be a PITA to make, requiring 2 pipes and either a coupler or welding. I actually know a welder but wanted to make this project as simple and relatively cheap as possible, so I played with pipe designs using dryer hose since it is easily bendable. Ghetto: yes. But it worked very well as it turns out. Overall, my total cost was about $225 to make this, although I think it could be done for less with cheaper filters.
https://uploads.tapatalk-cdn.com/20171104/46798bc208849f3a17569bc36b70cbc3.jpg
I came up with a 35 degree pipe in back and a 90 degree pipe in front. I decided to use 3 inch diameter pipe, however someone could use a smaller pipe considering the 2.25 diameter of the turbo inlet pipes. Btw, the pipes below are very good quality.
https://uploads.tapatalk-cdn.com/20171104/d63c2a730ef2317251787d4d83746525.jpg
INTAKE
Filter X 2
https://www.amazon.com/gp/product/B001NF4O62/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
* you can use similar/cheaper filters with same dimensions; I just like that these are oil-less and never need to be replaced. As another member pointed out to me, you can use another design filter and this may increase turbo induction noise vs AMSOIL filters.
Squirrelly 90 degree pipe
https://www.amazon.com/gp/product/B00D6MMZQG/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
Squirrelly 35 degree pipe
https://www.amazon.com/gp/product/B01GQU9H5Q/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
3in to 2.25in coupler X 2
https://www.amazon.com/Ronteix-Universal-Reducer-Coupler-Silicone/dp/B075STQ63T/ref=sr_1_19?s=automotive&ie=UTF8&qid=1509754684&sr=1-19&keywords=3%22+hose+coupler
Coupler hose clamps X 4
https://www.amazon.com/Uxcell-Adjustable-Screw-Clamps-52mm-76mm/dp/B00EZDMKCE/ref=sr_1_18?s=hi&rps=1&ie=UTF8&qid=1509764598&sr=1-18&keywords=3+inch+hose+clamp&refinements=p_85%3A2470955011
1. Measure 2.75 inches from the end of each side of the 35 degree pipe and mark it with the sharpie. Then use the hose clamps and clamp around the pipes at those areas. Use the sharpie to mark all around the pipe. Cut the 35 degree pipe at these areas. I did this using a vice clamp and a 3 inch cutting wheel, but you could use a hacksaw or circular saw of course.
2. Do the same thing with the 90 degree pipe, however cut off 5.5 inches from the side that will attach to the filter, and 3.75 inches that will attach to the turbo inlet.
****IMPORTANT: After you or a muffler shop cuts the pipes, just know that you need to be very careful about making sure there are no metal debris that may come off and get sucked into your turbos/motor. I used a dremel silicon carbide bit (X 2) and a wire wheel. Also make sure to clean the inside of the pipes thoroughly after they are cut. Don’t say I didn’t warn you.
3. Attach the filters and couplers
HEAT SHIELD
12 X 24 inch Aluminum sheet
https://www.amazon.com/Online-Metal-Supply-Anodized-Aluminum/dp/B073MH92NK/ref=sr_1_12?ie=UTF8&qid=1509759579&sr=8-12&keywords=anodized+aluminum+sheet
* I found a similar sheet at home depot for about $10
Heat reflector
https://www.amazon.com/gp/product/B002Q2T8R6/ref=oh_aui_detailpage_o00_s01?ie=UTF8&psc=1
Heat shield trim
https://www.amazon.com/gp/product/B01E7L2E1K/ref=oh_aui_detailpage_o00_s01?ie=UTF8&psc=1
1. In order to build the heat shield, you will want to create a cutout from cardboard based on the space in the engine bay. I just cut out a piece from an amazon box. Not much to say here, just make sure you leave room for the intake pipes too. Once happy with the shape, trace it onto the aluminum sheet and cut it out. I used a dremel tool with cutting wheel. (By the way, I was able to find my sheet from a hardware store with the small 90 degree bend already in it. You could always use small L brackets on the bottom to mount it in the car if you are unable to bend the piece of aluminum on your own.)
2. Trace the same shape onto the heat shield and cut it out. Stick it to the aluminum sheet. I did both sides because I had enough material.
3. Run the heat shield trim around the outside. When I was sure I was happy with the shape and everything fit well, I put a thin strip of super glue around the edges to make sure it stayed in place.
4. Mount the heat shield to the car. I used 3 short self-tapping screws without issue.
https://uploads.tapatalk-cdn.com/20171104/4148d15cf4b874c3ae0104e6e3c6f475.jpg
Sent from my iPhone using Tapatalk
I started to design my intake as a replica of the Roc-Euro setup, however found that the rear pipe would be a PITA to make, requiring 2 pipes and either a coupler or welding. I actually know a welder but wanted to make this project as simple and relatively cheap as possible, so I played with pipe designs using dryer hose since it is easily bendable. Ghetto: yes. But it worked very well as it turns out. Overall, my total cost was about $225 to make this, although I think it could be done for less with cheaper filters.
https://uploads.tapatalk-cdn.com/20171104/46798bc208849f3a17569bc36b70cbc3.jpg
I came up with a 35 degree pipe in back and a 90 degree pipe in front. I decided to use 3 inch diameter pipe, however someone could use a smaller pipe considering the 2.25 diameter of the turbo inlet pipes. Btw, the pipes below are very good quality.
https://uploads.tapatalk-cdn.com/20171104/d63c2a730ef2317251787d4d83746525.jpg
INTAKE
Filter X 2
https://www.amazon.com/gp/product/B001NF4O62/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
* you can use similar/cheaper filters with same dimensions; I just like that these are oil-less and never need to be replaced. As another member pointed out to me, you can use another design filter and this may increase turbo induction noise vs AMSOIL filters.
Squirrelly 90 degree pipe
https://www.amazon.com/gp/product/B00D6MMZQG/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
Squirrelly 35 degree pipe
https://www.amazon.com/gp/product/B01GQU9H5Q/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
3in to 2.25in coupler X 2
https://www.amazon.com/Ronteix-Universal-Reducer-Coupler-Silicone/dp/B075STQ63T/ref=sr_1_19?s=automotive&ie=UTF8&qid=1509754684&sr=1-19&keywords=3%22+hose+coupler
Coupler hose clamps X 4
https://www.amazon.com/Uxcell-Adjustable-Screw-Clamps-52mm-76mm/dp/B00EZDMKCE/ref=sr_1_18?s=hi&rps=1&ie=UTF8&qid=1509764598&sr=1-18&keywords=3+inch+hose+clamp&refinements=p_85%3A2470955011
1. Measure 2.75 inches from the end of each side of the 35 degree pipe and mark it with the sharpie. Then use the hose clamps and clamp around the pipes at those areas. Use the sharpie to mark all around the pipe. Cut the 35 degree pipe at these areas. I did this using a vice clamp and a 3 inch cutting wheel, but you could use a hacksaw or circular saw of course.
2. Do the same thing with the 90 degree pipe, however cut off 5.5 inches from the side that will attach to the filter, and 3.75 inches that will attach to the turbo inlet.
****IMPORTANT: After you or a muffler shop cuts the pipes, just know that you need to be very careful about making sure there are no metal debris that may come off and get sucked into your turbos/motor. I used a dremel silicon carbide bit (X 2) and a wire wheel. Also make sure to clean the inside of the pipes thoroughly after they are cut. Don’t say I didn’t warn you.
3. Attach the filters and couplers
HEAT SHIELD
12 X 24 inch Aluminum sheet
https://www.amazon.com/Online-Metal-Supply-Anodized-Aluminum/dp/B073MH92NK/ref=sr_1_12?ie=UTF8&qid=1509759579&sr=8-12&keywords=anodized+aluminum+sheet
* I found a similar sheet at home depot for about $10
Heat reflector
https://www.amazon.com/gp/product/B002Q2T8R6/ref=oh_aui_detailpage_o00_s01?ie=UTF8&psc=1
Heat shield trim
https://www.amazon.com/gp/product/B01E7L2E1K/ref=oh_aui_detailpage_o00_s01?ie=UTF8&psc=1
1. In order to build the heat shield, you will want to create a cutout from cardboard based on the space in the engine bay. I just cut out a piece from an amazon box. Not much to say here, just make sure you leave room for the intake pipes too. Once happy with the shape, trace it onto the aluminum sheet and cut it out. I used a dremel tool with cutting wheel. (By the way, I was able to find my sheet from a hardware store with the small 90 degree bend already in it. You could always use small L brackets on the bottom to mount it in the car if you are unable to bend the piece of aluminum on your own.)
2. Trace the same shape onto the heat shield and cut it out. Stick it to the aluminum sheet. I did both sides because I had enough material.
3. Run the heat shield trim around the outside. When I was sure I was happy with the shape and everything fit well, I put a thin strip of super glue around the edges to make sure it stayed in place.
4. Mount the heat shield to the car. I used 3 short self-tapping screws without issue.
https://uploads.tapatalk-cdn.com/20171104/4148d15cf4b874c3ae0104e6e3c6f475.jpg
Sent from my iPhone using Tapatalk