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Discussion Starter · #1 ·
For everyone that swears that a CAI is not worth while on our cars and that the stock airbox can supply enough air needed, I did a test. I have the EVO CAI and I wanted to try out my modfied airbox. I shaved the top of the box, cleared the bottom of it, added a 3.5" expensive hose to the box from the front of the car, and added an ITG. Well guess what, it pounded the EVO into the ground like a fence stake. No more EVO for me. I am only going to show the airmass but the hp is higher as well, by 3 - 5 hp over the EVO from a block 120.
Stock Box w/ stock filter, smoothed inners = 172 g/s
Stock Box w/ stock filter, smoothed inners, ram hose = 177 g/s
EVO CAI = 178 g/s
Stock Box w/ ITG, smoothed inners, ram hose = 184 g/s
Read this http://www.autospeed.com/A_0629/page1.html
It was 9vw23yrs (Jorge) and TTSchwing (Steve) that got me to do this and the article written above. I didn't have the tools to go Steve's route, so I made due with what I had.
Stock Box Top

Smoothed Stock Box, used dremel, sand paper, and love

Hose with to much space

Hose with filled in edges using insulation tape, the wire was removed so entrance was smoother later.

Isulation tape from home Depot

Bottom box with edges removed, water gate cut, and engine intake sealed

Front mount hose

Another front mount hose

Notice the wire holding it down under the bumper, gives a smoother entrance, bent horn up for more clearance

Top shot of the godzilla hose



[Modified by Kode, 4:40 PM 1-16-2003]
 

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Re: For all you CAI haters out there. (Kode)

Wow!!
Someone should buy stock boxes from VW, Mod them and resell as a kit like this!!
Hint, Hint
 

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Re: For all you CAI haters out there. (Kode)

Cool
How did you route the air pipe to the lower grill without crushing it?
(did you take of the back of the headlight or cut it or something?)
Cheers,
Jon
 

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Re: For all you CAI haters out there. (Kode)

Jorge T airbox mod is Numero Uno! The trademarked Yellow Jacket 3-1/2" duct hose is unbeatable. http://****************.com/smile/emthup.gif
 

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Discussion Starter · #7 ·
Re: For all you CAI haters out there. (TRBNIUM)

It takes some time and loving, but the end result is amazing. The tubing is crucial as well, you need to call warehouses and find expensive air duct tubing that will be in the range of $5 a foot, you can even try for a hose labeled as a water pump suction hose. That hose is extremely smooth compared to majority of hoses, even at the bends.
Someone should definately produce a aftermarket stock airbox after seeing the result here. This cost a grand total of $75 dollars, that is the ITG, hose, and isulation tape to make it solid.
 

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Discussion Starter · #8 ·
Re: For all you CAI haters out there. (big-jona)

quote:[HR][/HR]Cool
How did you route the air pipe to the lower grill without crushing it?
(did you take of the back of the headlight or cut it or something?)
Cheers,
Jon[HR][/HR]​
The tube fit through there with no problem, remember that I had a EVO CAI on there before so I had already removed all the plastic and I think I even moved the light switch thing when I installed the EVO. Basically follow the regular CAI instal instructions to get it to clear in there, no pinches anywhere.
quote:[HR][/HR]Jorge T airbox mod is Numero Uno! The trademarked Yellow Jacket 3-1/2" duct hose is unbeatable. http://****************.com/smile/emthup.gif [HR][/HR]​
Man you and Mike know it!!, I just got lucky since I have known Jorge longer than all of you
I am so glad that 9vw23yrs made me do this, just like old times right Jorge? TTSchwing also gave me the inspiration to spend more time on it then I would have normally, have you guys seen his carbon box, DAMN.


[Modified by Kode, 4:51 PM 1-16-2003]
 

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Re: For all you CAI haters out there. (Kode)

cripes.
very nice, very nice indeed http://****************.com/smile/emthup.gif
 

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Re: For all you CAI haters out there. (Kode)

that is a good idea but in my neck of the woods id be scared a squirrel will make his way up in there and go for a nice ride someday.maybe a grille on the front cure this issue?
hmm ill have to think about this now....
 

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Discussion Starter · #11 ·
Re: For all you CAI haters out there. (got_boost)

I run my cover over it, but at the track take it off. That poor squirrel, he would be so pissed!
 

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Re: For all you CAI haters out there. (Jetta_1.8Tip)

Nice. http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif
 

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Re: For all you CAI haters out there. (Simans82)

LOL busted
Thank for the kind words, I'm glad you posted it. I do not have the patience/time to do a nice write up. I did all my testing on stage 3 so I did not have nothing else to compare too.
BTW David and I did the same a while back on R/C cars competing at a national level.
 

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Re: For all you CAI haters out there.

Cool deal even though for some reason here at work I can not see the pics. Looks like the ITG filter alone pushed your numbers beyond the EVO. Makes you wonder what a ITG type cone on the end of the EVO would do.
 

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Re: For all you CAI haters out there. (MRP2001GTi)

the only reason I wont do that, is because It is almost like a snow plow!
if it rains or what ever else, it might pick it up like a vacume.
keep an Eye on it and let us all know!
good write up W/pics http://****************.com/smile/emthup.gif
 

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Re: For all you CAI haters out there. (Kode)

which gear did you do the testing at? Would you expect to see more "ram" effect at higher gears?
And the numbers dont lie, good job. Looks like an EVO intake will probably be up for sale soon huh?
 

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Re: For all you CAI haters out there. (spoolin)

I have the same concern. I plan to do this mod but to leave the section for when water gets sucked up. I'm sure that extra filter area does make a difference in performance though. I'm just not willing to take that risk.
 

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Re: For all you CAI haters out there. (new 337)

quote:[HR][/HR]which gear did you do the testing at? Would you expect to see more "ram" effect at higher gears?[HR][/HR]​
You'll create sufficient velocities to induce true pressurized intake at about 190mph...before that, the air is just cooler than underhood.
quote:[HR][/HR]
And the numbers dont lie, good job. Looks like an EVO intake will probably be up for sale soon huh?
[HR][/HR]​
I know it's almost cliche, and everyone thinks it's the end-all THING...but any thoughts on dyno runs to see if the block 120 data is backed up by a the "other" big test?
 

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Re: For all you CAI haters out there. (too fast)

i have the same done on my jetta. sounds great with the hyperboost DV http://****************.com/smile/emthup.gif and if you look in your airbox, there is a small hole on the bottom where water and moisture drains out. i have driven in rain storms and mild flooding. i was paranoid about sucking in water, but i checked the airbox and filter, and not a drop of water was to be found on the top side of the ITG filter.
 
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