[Yiros]

Hello All,

I have started designing a custom airbox for my pod filter. I have nearly finished the cardboard box. So far it has taken around 6 hours to get the shape right. The airbox accommodates the factory cold air induction pipes and gives the ignition coil (NA only) just enough clearance. I decided to add an additional cold air pipe for the hell of it.

I was considering making the final version out of aluminium or fibre glass. However looking at the curves and bends, I think it will be much easier using the cardboard box as a meld for fibre glass.

Hopefully I can start on the fibre glass during the week or next weekend.

I will post more pics as I progress further.

Cheers

Andrew

[PK]

Awesome mate. Let me know how it goes (cos u know i'm interested in that stuff).

I'll be starting mine in the next month or so...

PK

[Darren]

Looks like the right idea mate. Im keen to see the final result as it will give me a few clues. Im thinking the Aluminium route myself as I have a mate who is a fabricator. Still if the glass one looks good I'll change ideas as quick as a Sup running 20lbs boost :nasty:

Cheers gang
Darren :to_become_senile:

[TEFE]

The modified air box has got me thinking as well. It would stop a lot of heat from the engine bay as well as stopping the other kind of heat that a pod can draw....
Chris.

[PK]

TEFE, on Nov 6 2005, 08:13 PM, said:

The modified air box has got me thinking as well. It would stop a lot of heat from the engine bay as well as stopping the other kind of heat that a pod can draw....
Chris.
<{POST_SNAPBACK}>

Indeed. But the issue for me is using a material that will not draw IN any heat. Keeping heat out is the easy part.

Aluminium appears to be way to go, but it needs to be insulated in some way...

Daz - will fabricating it make any difference?

PK

[Yiros]

The_Jackal, on Nov 6 2005, 07:40 PM, said:

nice man nice, dont spose you wanna help me do one for the MK3????
i wouldnt know where to start especially the fiberglassing...
<{POST_SNAPBACK}>

No probs - I can give you a hand once I sought mine out. I haven't done much fibre glassing myself however, my dad has done a bit (repairing the front spoiler on the old S3 commodore) and I have access to SAS Paint and Panel.

[Yiros]

PK2811, on Nov 6 2005, 07:42 PM, said:

Awesome mate. Let me know how it goes (cos u know i'm interested in that stuff).

I'll be starting mine in the next month or so...

PK
<{POST_SNAPBACK}>

I will try and protect the cardboard box so it could possibly make more than one air box. If mine works out well, you guys are more than welcome to copy/steel/borrow my setup.

Wish me luck!

[PK]

yiros, on Nov 6 2005, 10:03 PM, said:

I will try and protect the cardboard box so it could possibly make more than one air box. If mine works out well, you guys are more than welcome to copy/steel/borrow my setup.

Wish me luck!
<{POST_SNAPBACK}>

Good luck mate! :ok:

PK

[Darren]

PK for what its worth the Fabrication bit comes down to fact Im a lazy bastard an I'll let my mate get his hands dirty :lol:

Other than that the heat shouldnt be as bad as what I have at the moment, a bloody great POD hanging out in the breeze under the bonnet sucking up copious quantities of nicely PRE-HEATED air :(

Cheers mate
Darren

[Reaper]

Hey Andrew,

Will love to see the finished product BUT mate, I can't believe no one else laughed when you said it took you 6 hours to fashion a cardboard box!! siht, made me laugh!! :D

Dude, tell me this was an act of humour or the actual box is gonna take you 20 years - hehe, crikey I'm still chuckling at this one.

Gav

PS- no pay out intended if it did take you that long slow poco rodriguez :P

[Reaper]

Nice play on words - me likey! :ok:
Gav

TEFE, on Nov 6 2005, 06:45 PM, said:

The modified air box has got me thinking as well. It would stop a lot of heat from the engine bay as well as stopping the other kind of heat that a pod can draw....
Chris.
<{POST_SNAPBACK}>

[PK]

Yiros,

Im getting a template for a DIY air box sent to me in the next few weeks.

Might be able to share the wealth if your interested. Save you a lot of work. Not that you havent done enough already!

PK

[Yiros]

PK2811, on Nov 11 2005, 12:42 AM, said:

Yiros,

Im getting a template for a DIY air box sent to me in the next few weeks.

Might be able to share the wealth if your interested. Save you a lot of work. Not that you havent done enough already!

PK
<{POST_SNAPBACK}>

Cheers for the offer. Hopefully I have mine made by then. If not then count me in.

[Yiros]

Hey People,

I thought I would give you all an update of my custom airbox.

I decided to get my backside into gear and start fibre glassing.

I purchased 2 packets of fibre glass mat from Sprints ($8 per pack), I traced the box out on the fibre glass and cut out each piece (see attached photo).

I then mixed the resin and hardener (remember to wear latex gloves and a face mask – I looked more like Dr Yiros :lol: )as this is some potent siht…

I applied my first layer of fibre glass (one side at a time) to the box and brushed resin all over it. I then applied the second layer and let cure for 24 hours.

The following day, I separated the cardboard from the fibre glass (not very successful in some areas). The box is rather rough and will need 2 more layers of fibre glass (one on each side) and a siht load of sanding. Since I ran out of fibre glass mat and resin, I will have to continue some other day.

Cheers

Andrew

[TEFE]

Taking shape Andrew, :claps: how are you going to finish the top?? Are you going to use a compressable foam to seal to the under side of the bonnet?? Plus are you running the other piping though to the air intake under the indicator lens?
Chris

[PK]

Looks the goods mate. :ok: ahem... sorry... Dr.

:hmmm: could be a very lucrative business for you...

PK

[Yiros]

TEFE, on Nov 21 2005, 09:53 PM, said:

Taking shape Andrew, :claps:  how are you going to finish the top??  Are you going to use a compressable foam to seal to the under side of the bonnet?? Plus are you running the other piping though to the air intake under the indicator lens?
Chris
<{POST_SNAPBACK}>

Hey Chris,

I haven't worked out the top bit yet. I was waiting to see how the bottom turned out before I measure up and shape the top. I was considering making a lid that will seal against the box and remain in place either by screws or by pressure.

I ran the extra bit of induction through the guard down to the brake duct beneath the indicator. Since I don't have a TT I thought I might as well use the factory intercooler cut outs (I think). I don’t have the extra bit of induction installed at the moment. It was purely for the photos. Hopefully my airbox will receive plenty of cold air when I am done.

I am even considering taking my car to Fours n More for have 3 dyno runs to compare factory setup, Airpod and Airpod with custom airbox.

Cheers

Andrew

[Yiros]

PK2811, on Nov 21 2005, 10:04 PM, said:

Looks the goods mate. :ok: ahem... sorry... Dr.

:hmmm: could be a very lucrative business for you...

PK
<{POST_SNAPBACK}>

I don't think anyone could afford me :lol:

The fibre glass option isn’t the easiest option as it is very time consuming and the materials aren't cheap. I am sure the end product will result in a much better fitment and I am guessing that the insulating properties of fibre glass would be better than aluminium. (Don’t quote me as I am too lazy to check this out in my old engineering books.) The advantage of using fibre glass over aluminium is that it is easy to shape and bends aren’t a problem plus I was able to let the box cure in the engine bay allowing the box to take shape for a nice snug fit.

So far I have spent $16 for the fibre glass mat, $3 for paint brush to apply the resin, I have used a tin of resin approx $20 and the hardener cost about $7. I need to buy 2 or 3 more fibre glass mats, another tin of resin and another paint brush.

That works out to be around $90 in materials (not including a box of latex gloves and surgical masks - kindly donated by Diana).

Not to mention about 12 hours of labour so far @$100 per hour :lol:.

Oh well, I can safely say that I am the only person in Oz with a $1500ish airbox :D

Having said all that, I am still more than happy to help anyone who wants to take the fibre glass option (I don't know why as I am still trying to remove glass splinters from my arms and legs :( )

[Boost Samurai]

Looks like an awesome project Yiros. Keep up the good work.

My pod simply has an aluminium heat shield on one side of it between the pod and the radiator. Don't know how effective it is but I guess it's better than nothing at all.

In any case, I reckon I'll have a crack at it too, just for the TT boyZ :D

That and the fact I now have 6 Defi gauges on their way to me and I have no idea where or how to mount them. So this would essentially be my first attempt at using fibreglass before I go and plaster it all over my interior in a vein attempt to make a custom A-Pillar gauge holder. :)

Keep us updated on your million dollar project ;)