Upgrading CAI

[FordNut]

Latest project, work in progress. Changing from the 4" flex hose to nice, smooth mandrel bent 4-1/2" aluminum tubing. Ought to flow a little more air, maybe put me over 700 rwhp!

[ImpalaSlayer]

nice, should look good when done. why dont you just move the battery over? it was super easy.

[FordNut]

I want my filter shielded from engine compartment heat.

[breeze]

is there a way u can run it into the square in the bumper???

[guspech750]

Looking good. Just another option for us contemplating the move to Supercharged stardom.

[FordNut]

Not many other options for locating mine to get outside air. Passenger's side fenderwell has a B&M auxiliary tranny cooler with integral fan. It's currently disconnected because I upgraded the primary trans cooler to a monster cooler, but I'm leaving it in place to use for a rear diff cooler in the future. There's also an intercooler water pump mounted in there somewhere. Driver's side fenderwell has the pump for a Snow Performance H2O/Meth injection system I haven't bothered to dial in yet. It also has a CAI scoop mounted underneath the fenderwell with a huge duct to direct outside air to the holes in the radiator support panel behind the headlight. Used to be a Mustang part, but I modified it to fit. Oh, and both sides also have the ducting in there for the disc brake cooling.

[LANDY]

Not many other options for locating mine to get outside air. Passenger's side fenderwell has a B&M auxiliary tranny cooler with integral fan. It's currently disconnected because I upgraded the primary trans cooler to a monster cooler, but I'm leaving it in place to use for a rear diff cooler in the future. There's also an intercooler water pump mounted in there somewhere. Driver's side fenderwell has the pump for a Snow Performance H2O/Meth injection system I haven't bothered to dial in yet. It also has a CAI scoop mounted underneath the fenderwell with a huge duct to direct outside air to the holes in the radiator support panel behind the headlight. Used to be a Mustang part, but I modified it to fit. Oh, and both sides also have the ducting in there for the disc brake cooling.
all that stuff you have in ther is frigging awsome!:burnout:
by the way your engine comparment looks like a dream.:beer:

[bob6364]

Jumpin' Geezus you getting ready for a Cannonball run?... :D

[FordNut]

Not many other options for locating mine to get outside air. Passenger's side fenderwell has a B&M auxiliary tranny cooler with integral fan. It's currently disconnected because I upgraded the primary trans cooler to a monster cooler, but I'm leaving it in place to use for a rear diff cooler in the future. There's also an intercooler water pump mounted in there somewhere. Driver's side fenderwell has the pump for a Snow Performance H2O/Meth injection system I haven't bothered to dial in yet. It also has a CAI scoop mounted underneath the fenderwell with a huge duct to direct outside air to the holes in the radiator support panel behind the headlight. Used to be a Mustang part, but I modified it to fit. Oh, and both sides also have the ducting in there for the disc brake cooling.


all that stuff you have in ther is frigging awsome!:burnout:
by the way your engine comparment looks like a dream.:beer:


OOPS, forgot about the remote transmission filter on the passenger's side.

[ImpalaSlayer]

jesus dude. whats next, pcm cooling?

[ImpalaSlayer]

lol Brian will have one of these b4 long

http://images.tigerdirect.com/skuimages/large/C283-1160-main.jpg

[bob6364]

LOL...its a pacemaker for his cpu ....

[FordNut]

Then between the frame rails it's a whole 'nother story.

Driver's side frame rail has the remote engine oil filter, the engine has the CVPI engine adapter for oil cooler, between the air dam scoop and the sway bar is the oil-air engine oil cooler with the dual 7" fans mounted on the cooler, then on the trans lines are the dual trans temp sensor blocks (to measure hot & cooled trans fluid temp). Just behind the bumper is the LFP upgraded dual-pass Lightning heat exchanger with dual 8" fans. I'm just about out of space.

[bob6364]

Then between the frame rails it's a whole 'nother story.

Driver's side frame rail has the remote engine oil filter, the engine has the CVPI engine adapter for oil cooler, between the air dam scoop and the sway bar is the oil-air engine oil cooler with the dual 7" fans mounted on the cooler, then on the trans lines are the dual trans temp sensor blocks (to measure hot & cooled trans fluid temp). Just behind the bumper is the LFP upgraded dual-pass Lightning heat exchanger with dual 8" fans. I'm just about out of space.

Your car would be alot faster without the 200 pounds of extra coolers and the extra 10 gallons of fluids....:P:D

[FordNut]

Maybe, but it's plenty fast as it is....

[DEFYANT]

Friggin awsome! I like it - all of it!

[FordNut]

Took the pipes to the welder today. Gonna be done in 2 sections, I tried it in one piece and it's just too hard to install/remove that way. Got the silicone coupling hoses today, so look at the last pic to see where it's gonna come apart. The blue tape is where the sections will be welded together. Long term, it will probably be powdercoated black.

[ImpalaSlayer]

nice, did you get those from frozenboost.com?

also why is your IC res mounted on an angle

[FordNut]

Found a great price at Votion.

Mounted the reservoir the way it fit best, needed to be as low as possible so the CAI hose would fit between its hose fittings and the hood. It's kind of crooked too for the same reason, for space it needed to be as far forward as possible so it's pretty much against the radiator. Probably wouldn't have as many space issues with the OEM radiator, but the Griffin is thicker than the stocker.

[Big Black Beast]

If you had a Mustang, you'd have to get another one to fit all that in!

[TAKEDOWN]

NICE, wow 4 1/2 pipes... do the metal pipes keep it cooler than the plastic ones?

[FordNut]

NICE, wow 4 1/2 pipes... do the metal pipes keep it cooler than the plastic ones?

Probably not, but they're smooth inside instead of ribbed so they should flow a lot more air. Actually the bare aluminum pipes would probably result in a higher temperature air charge than plastic. I'll be having them coated with black thermal barrier treatment (Jet Hot type coating).

[FordNut]

Pipes are welded together, got all the silicone couplings and hose clamps, ready to send out to the powdercoating shop.

[babbage]

Wow lot of work. looks good. I've seen a design also (done to a CV) where the radiator is lowered 2-3 inches and you put the cone filter right between the grille and radiator.

Tell me again about why you didn't just do the battery relo - straight shot out and then perhaps make a small heat shield out of say 1/8" thick aluminum?

[FordNut]

Wow lot of work. looks good. I've seen a design also (done to a CV) where the radiator is lowered 2-3 inches and you put the cone filter right between the grille and radiator.

Tell me again about why you didn't just do the battery relo - straight shot out and then perhaps make a small heat shield out of say 1/8" thick aluminum?

I want outside air to supply my filter, not engine compartment air.

From a previous post in this thread...


Not many other options for locating mine to get outside air. Passenger's side fenderwell has a B&M auxiliary tranny cooler with integral fan. Driver's side fenderwell has ... a CAI scoop mounted underneath the fenderwell with a huge duct to direct outside air to the holes in the radiator support panel behind the headlight.

Plus I don't want to re-do the electrical system or cover up my air suspension pump with a battery.

[Mike]

lookin' good :banana:

[Pat]

I noticed the ducting is rubbing/contacting/resting on the resevoir cap. Is that a concern for you?

The change looks better for sure and after heat resistant paint/coating should improve response.

Regards,

[FordNut]

It is resting on the cap because the clamps aren't tightened. When securely attached, it isn't touching the cap and I put a small indentation in the pipe to clear the cap and prevent rubbing. There are also a couple of places on the bottom that needed dents to clear other components (intercooler hose, blower belt tensioner).

[SC Cheesehead]

Nice set-up!

Do you think this configuration could be adapted for an Eaton conversion?

[2,4shofast]

Brian,

I love seeing all the progress with your Marauder....you have done such a awesome job with it!:bows:

[FordNut]

Nice set-up!

Do you think this configuration could be adapted for an Eaton conversion?

Probably, but with the cost in materials, welding, and countless man-hours put into it nobody would buy it. If anybody wants do have it, it's a DIY project, but the attached pics should be enough documentation.

I didn't document the air filter shield, it started out as an Airaid CAI for a Wrangler, part # 310-144, but it took a lot of mods to adapt it to the MM. The velocity stack came from Turbohoses.com, but it also had to be modified since the biggest they have is 4". Actually the whole thing would be a lot easier to implement if you stick with 4" tubing.

Of course, you could also use the box that FIT of DR uses for their air-air intercooled setups.

edit: it could possibly be done with 2 90 degree bends and 2 45 degree silicone couplings along with 2 straight coupling hoses.

[ImpalaSlayer]

Nice set-up!

Do you think this configuration could be adapted for an Eaton conversion?


not sure why you would, unless you have 400 things like Brian has its much easier to just move the battery, its like 3 wires.

[justbob]

That one wicked lookin setup Brian!

[FordNut]

Shipped it out today for "blackening".

Been working on another mod while doing this one, also shipped the brackets for it to be powdercoated. Once they come back, I'll start a thread about this idea. Dunno if it'll increase power but it might reduce/prevent oil leaks due to crankcase pressure... then again maybe it's just another test that won't work out and I'll pull it back off.

[offroadkarter]

I want my filter shielded from engine compartment heat.



soooo make it go out the pass side instead of the drivers?

Or just get one of these and put the filter on the end :P

http://denalioffroadclub.com/myPictures/big%20champ%20snorkel.jpg





But whatever, your car... Are you going to wrap it in insulation to?

[Glockafella]

Gotta Bar-B-Que missing parts in your backyard offroad?

[RR|Suki]

what kinds of temps are you seeing at the MAF with the air scoop deal? For what it's worth, I would see a couple degrees under outside temp (bumper sensor) when my intake was where it is in the pic.

https://www.msu.edu/~taylorab/mapas.jpg

[Glockafella]

Every MM should have been built like yours man!

[FordNut]

soooo make it go out the pass side instead of the drivers?


...Passenger's side fenderwell has a B&M auxiliary tranny cooler with integral fan... driver's side has has ...a CAI scoop mounted underneath the fenderwell with a huge duct to direct outside air to the holes in the radiator support panel behind the headlight.


... Are you going to wrap it in insulation to?


... I'll be having them coated with black thermal barrier treatment (Jet Hot type coating).

I think both questions have already been addressed.

[FordNut]

what kinds of temps are you seeing at the MAF with the air scoop deal? For what it's worth, I would see a couple degrees under outside temp (bumper sensor) when my intake was where it is in the pic.

Dunno what the temp is at the MAF.

I relocated my outside air temp sensor, it's just in front of the radiator support panel where the March ram air system dumps outside air. After that I can measure IAT2 after the blower but not IAT at the MAF through the scangauge. My Autometer IAT gauge is connected to read water temp coming out of the heat exchanger after the blower.

[offroadkarter]

I think both questions have already been addressed.


Yep that answers those :D

[FordNut]

Pipes are back with ceramic coating. Soon I'll see if I make any more power with the upgraded setup. It sure looks better.

[Speed]

Man that looks "Sick." I like that black on black.

[Local Boy]

Very nice Brian!

I got some left over 3 inch piping if you want to build a modified cross over tube...(Big Smile/Wink) Just say the word, and it's yours... :)

Aloha

[tjl006]

Very sharp, really looks good. Hopefully it adds a few extra horses too.

[Joe Walsh]

Man that looks "Sick." I like that black on black.

+1!

Brian, that is just plain "Darth Vader BadAZZ"!!!

[2,4shofast]

They came out amazing!:beer:

[Glockafella]

I want it!!! I want it bad!

[swordfish]

that is just plain "Darth Vader BadAZZ"!!!

I can't think of no better way to say it! :bows:

[FordNut]

Latest update.
I didn't really drive the car much after getting the intake tube redone, it was wintertime and we had bad weather, plus I was working on some other projects. Finally it's getting nice outside so I've been driving it around. First thing I found is that it wil set the CEL after awhile, bank 1 lean and bank 2 lean codes. I expected the increased airflow to change the MAF readings so the MAF transfer function needed adjusting. I didn't expect it to make such a big difference at low throttle openings but I learned another lesson.

So what I did is this: I have a flip chip which can run up to 4 programs and you can switch on the fly. I modified the MAF transfer function in my tune (I have the Pro Racer's Package) so I had 3 different tunes. One of them I multiplied the MAF transfer by 0.9 (-10%) and another one I multiplied by 1.10 (+10%). I did this because I wasn't sure which way the MAF transfer function needed to change. I fired it up with the standard and it ran ok, just a little rough at startup. I tried again with the -10% and it was terrible, barely ran tried to die. I tried with the +10% and it fired up and went to idle just fine. Ran good so I drove it around awhile. It set the CEL again. I made another tune with the MAF transfer function increased by 20% and it seems really good now.

I know it needs a dyno tune to get it tuned just right, but it seems really good so far. Initially it seems to me I'm moving about 20% more air at a given rpm than what I was before. I wonder how that is going to affect the rwhp? Dyno tune is coming up sometime this month, I'll post the data then.

[LeoVampire]

I hope the dyno tune shows the results you want to see.

@ least in the mean time you got it usable. So after 20% no more code's?

[FordNut]

Not yet. It would be nice if it set a rich code so I could split the difference.

[LeoVampire]

Not yet. It would be nice if it set a rich code so I could split the difference.

Are the Cat's still in place? I hope it will not burn them out on you in the mean time waiting for the dyno set up.

[FordNut]

Last time I had it dyno tuned the tuner told me changing from the flex tubing to the mandrel bent ought to get me 20-30 hp so I hope to be over 700 on 91 octane pump gas.

[LeoVampire]

Last time I had it dyno tuned the tuner told me changing from the flex tubing to the mandrel bent ought to get me 20-30 hp so I hope to be over 700 on 91 octane pump gas.

I am sure the flow is much better seeing you got the MAF complaining about the change.

[FordNut]

Shouldn't hurt the cats, I'll be driving in closed loop so the AFR is always around 14.7:1 anyway. But the cats do need to be replaced because they rattle from when I had to hammer dents in them to clear the modified crossmember. That was during the transmission upgrade project. I've got replacement cats and flanges, just need to get the tubing and have the welding done.

[LeoVampire]

Shouldn't hurt the cats, I'll be driving in closed loop so the AFR is always around 14.7:1 anyway. But the cats do need to be replaced because they rattle from when I had to hammer dents in them to clear the modified crossmember. That was during the transmission upgrade project. I've got replacement cats and flanges, just need to get the tubing and have the welding done.

Oh well the price we pay to modify a car sometimes I guess.

[FordNut]

Oh well the price we pay to modify a car sometimes I guess.

I wasn't real happy with them anyway. The shop that put them together didn't follow my instructions. Everything else in my exhaust system is stainless except the pipes between the cats and flanges. I had them ceramic coated but it's not the way I would have preferred it to be done.

[LANDY]

700rwhp sounds good. and it must be a handfull at WOT.
keep us posted on the new #'s

[ImpalaSlayer]

700rwhp sounds good. and it must be a handfull at WOT.
keep us posted on the new #'s


what he said! seems it took alot to get it to run right with just the upgraded intake.

[FordNut]

It took me a lot, a decent tuner would have been done with it in 5 minutes!

Surprising to me it took a 20% adjustment. It would be nice if 20% more air = 20% more power!

At WOT? I dunno it hasn't been there in quite awhile. Half throttle or maybe a little over half and it's kind of ridiculous. Honestly it's easier to handle than it was with the ProCharger D1SC. The PC was just violent acceleration sort of like a 2-stroke bike.

[ImpalaSlayer]

It took me a lot, a decent tuner would have been done with it in 5 minutes!

Surprising to me it took a 20% adjustment. It would be nice if 20% more air = 20% more power!

At WOT? I dunno it hasn't been there in quite awhile. Half throttle or maybe a little over half and it's kind of ridiculous. Honestly it's easier to handle than it was with the ProCharger D1SC. The PC was just violent acceleration sort of like a 2-stroke bike.

i miss my old 2 stroke bike. but the "a lot" i was talking about is the 20% hope you make big numbers! or should i say bigger

[FordNut]

i miss my old 2 stroke bike. but the "a lot" i was talking about is the 20% hope you make big numbers! or should i say bigger

Cool. I assumed "a lot" meant a lot of time and effort. I had numerous 2-stroke dirt bikes but the one 2-stroke bike I remember most was the H3? Kawasaki 750 triple cylinder. A rocket.

[ImpalaSlayer]

Cool. I assumed "a lot" meant a lot of time and effort. I had numerous 2-stroke dirt bikes but the one 2-stroke bike I remember most was the H3? Kawasaki 750 triple cylinder. A rocket.

you kidding me>? that thing must have ripped! didn't even know they made such a thing

[FordNut]

I believe it was '73-'75 or something like that. It was phased out when the Z1 900 came out. It was quicker than the 900 but not as good for an all-around bike. Great cafe racer though. Triple upswept expansion chambers, clip-on type handlebars, individual K&N filters. Hard to keep the front wheel on the ground.

[FordNut]

Did some datalogging and more adjustments to the MAF transfer function. Bottom end turned out to need a 35% increase, midrange varied between 20-30%. Can't do the top end without a dyno. Datalogged STFT's and MAF counts, kept tweaking MAF transfer function until the STFT's stayed aroung 1.0 (actually varied between .96 and 1.04) so I should be good for part-throttle driving until I get it tuned.

[LeoVampire]

Did some datalogging and more adjustments to the MAF transfer function. Bottom end turned out to need a 35% increase, midrange varied between 20-30%. Can't do the top end without a dyno. Datalogged STFT's and MAF counts, kept tweaking MAF transfer function until the STFT's stayed aroung 1.0 (actually varied between .96 and 1.04) so I should be good for part-throttle driving until I get it tuned.

But I am sure you will be a happier man once you get it set up right on the dyno. At in the mean time she can be used if you want.

[cougar9150]

Damn, I love the way it looks Fordnut. How does it sound when you hit the gas? Any different than a typical setup with the inlet on the passenger side?

I think it looks clean, and almost stock like a Roush setup. I may be hitting you up for some dimensions used to bend the pipes.

[FordNut]

Between the blower and the exhaust, you don't really notice the intake sound. I haven't seen any of the passenger-side setups so it's hard to compare. It does have more intake sound than the closed-box type air filter boxes.

[justbob]

That looks VERY nice! Just looks mean..