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2G 4.5" Cold Air Intake Mod

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bpe121212

15+ Year Contributor
59
2
Apr 24, 2006
Lynchburg, Virginia
I realize that there are many way's to skin a cat, but here is a brief overview of how I made a 4.5 " cold air intake mod for my 1995 Eagle Talon. I wanted to get the air filter out of the engine bay to attempt to reduce my intake air temps as much as possible. This mod reduced my Intake temps by ~ 15 degrees! This has allowed me to run 3 more pounds of boost with no knock without changing timing or Fuel. I am now running 27 PSI of Boost at WOT ( 8 RPM, 11.5 A/F, and 19 degrees Timing advance ). I am really happy with how it all turned out. A nice performance upgrade for less than $140.

Here is what was involved:

4.5 " SS pipe from Woolf Aircraft (had them cut one leg at 4 inches and the other at 0.5 ") Cost = $75
Item # 450-065-450-090-304, Bent Elbow on Woolf Aircraft Products Inc.

K&N 4.5" filter (part number-RU-4260) from K&N. Cost = $39.00
K&N RU-4260 $38.99 - Universal Air Filters, Universal Rubber Filter

Extreme PSI 4.5 " Coupler and 2 - 4.5 " T Clamps. Cost = $20.95EXTREME PSI : Your #1 Source for In Stock Performance Parts - Extreme PSI 4-Ply Silicone Coupler: 4.50" I.D.
EXTREME PSI : Your #1 Source for In Stock Performance Parts - Clampco Stainless Steel T Bolt Clamp : Fits 4.50" I.D. Coupler

Rubber Shock Coupler and aluminum brace with SS nuts and 1- 10 mm long 8/1.25 SS bolt and washer (had these in spare bin). I also had a MAS to 4.5" coupler from a previous ebay intake kit that I had purchased for my son's car. I do belive that entire kit was ~ $40. The rubber shock coupler that connects the lower pipe to the car via the aluminum brace is really useful to allow movement of the entire intake system when the motor moves during strong pulls.

I also made a 2" high by 6" long by 4" wide dense foam block that I attached below the MAS for support (used a 30 mm bolt through half of the foam block screwed to available welded nut and heavy duty double sided tape to attach the block to the base sheet metal) for support. You can see this in the first pic just under the MAS.



Total Cost was ~ $135


I do plan on polishing the SS pipe and making a grid screen to protect the
new K&N from road ware in the near future. I will be sure to post these pics as well soon.

Here are a few pic's of what I have done so far:
 

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I am sure that others have done this before, but I was not able to find out the details of how to do it with a 4.5" pipe, so I just thought that I would post what I had found out as I put this together for anyone that might be interested. by the way, No bubbles to be burst here!

Just trying to help if I can, since I have learned so much from so many others on this site!

Pres
 
Ever stick your hand over a turbo while it's spinning?

Yeah even at idle it'll suck your hand right to it. Now imagine under load. You'll suck up water driving through a puddle or even if it's raining hard enough. There is a lot of vacuum.
 
Ever stick your hand over a turbo while it's spinning?

Yeah even at idle it'll suck your hand right to it. Now imagine under load. You'll suck up water driving through a puddle or even if it's raining hard enough. There is a lot of vacuum.

Ever seafoam your car? Same principle. Read through the "Seafoam Works" Thread and you'll see a long discussion about hydrolock, and how hard it is to do it.
 
Well I'll have to agree with "viprez586". My air filter on my 95 GS-T is in its factory location. So I was just slowly puttin along one morning on my way to work after a a storm from the previous night. And ended up going through a small puddle of water just a couple of feet away from my work and ..............:banghead:! So I be damned if I go through puddles again.

Poor 6-bolt rod......:cry:
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Well I'll have to agree with "viprez586". My air filter on my 95 GS-T is in its factory location. So I was just slowly puttin along one morning on my way to work after a a storm from the previous night. And ended up going through a small puddle of water just a couple of feet away from my work and ..............:banghead:! So I be damned if I go through puddles again.

Poor 6-bolt rod......:cry:
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rest in peace....... :pray: LOL
 
Hey man, that's a killer job, and to hell with all the haters.
I'm sure he knows about all of the other people that have done their CAI's for less.
You all get what you pay for!

I have a track day coming up on the 25th, and you can bet your arse I'll have one of these in my engine bay.

I'm gonna one up you though, and get an Outer Wear.
If it'll fit, I'll run this filter.
RU-3480 - K&N Universal Air Filters, Universal Rubber Filter
With this Outer Wear.
RU-3480PK - K&N Filter Wraps, Air Filter Wrap
They are water repellant and can survive in rain.
With your set-up, can you reinstall your splash shield?
That would be key to keeping water off of your filter, but I'm sure you'll switch back to an underhood filter in the winter.

I have a DD now, so when it's raining, I won't drive my GSX...

The hole for the stock IC Piping to pass thru kinda messes everything up.
I may try and enlarge that opening and utilize it for passage into the fender.
And using 4.5" mandrel bent tubing is nice, but not necessary.
The inlet side of the MAS is octagonal IIRC so all you'd need to do is figure out the area of the MAS inlet and choose a tubing diameter that will provide just a touch more area and you're golden.
I'll be right back with my area findings...
 
The area of the 2g MAS Filter Adapter Inlet is ~11in^2
4" tube has a sq area of 12.57in^2
4" tube is all that's required for a little more volume of air to flow into the inlet.
 
I already had the 4.5" MAS to Pipe adapter so that is why I went with 4.5 pipe. I am sure the 4.0" would work fine as well. All I know is this mod has been a great way to get more HP (~ 20HP gain) on my car and I am very pleased with how it turned out. I just can't seem to stop tweaking on this car!!!!

Thanks for the feedback!

Pres
 
Yeah, I have the 4.5" Filter Adapter too, but I'll just use a 4.5" - 4" coupler.
Your's turned out really nice.
I'm going to mock mine up tomorrow and order the tube on Monday.
Did you know about the Outer Wear Pre-Filter?
I use them on my Yamaha Banshee for years, and my filter doesn't ever need to be cleaned.
 
Strm trpr, Thanks for the heads up on the outer ware prefilter! Excellent idea indeed! I can use this until I finish my protection box to go around the filter.

I am currently in the process of polishing the SS pipe. Boy, what a PITA this process is!!!
I guess nothing worthwhile comes easy!

I must also agree with 97gstnick that, you can definitely save a bit of money going for a 4" aluminum version of the pipe, but I just wanted a 4.5" SS pipe and Woolf was where I found what I was looking for. I have polished SS Intercooler pipes from ETS and just wanted to stick with SS.

If anyone has any good ideas on fabricating a protection box for the filter which will allow for the greatest amount of flow, but keep the filter out of the elements. please let me know. I have done some preliminary research and have not yet found what I am looking for.


Thanks!


Pres
 
I do not know 1g's at all, WTF am I looking at?

LOL

That is the upper half of my CAI. The fiberglass plate bolts to the frame; there is an elbow under it going to the filter, and the chrome piece sticking out of the top elbow connects to a pipe going over to the turbo. That pipe is made from off-the shelf modular intake parts, and connects with v-band style clamps, while the lower part is blasted and painted PVC. The tank sitting next to it is a coolant overflow tank that I made from .090 aluminum.

There are more pics and details in these links from my build blog (towards the bottom in both):

Part 6

Part 11

And this pic shows the intake pipe connected to the part above ^^^, before I finished up the stainless line to the catch can:

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Just mocked up a template out of cardboard to see how it's gonna fit.
It'll be cheaper for me to do 4.5" mandrel bent pipe.
Just ordered the same 4.5" coupler as above but in blue, and 2 T-Bolt Clamps.

I already have a 4.5" ID Vibrant Air Filter from Extreme PSI.
EXTREME PSI : Your #1 Source for In Stock Performance Parts - Vibrant Performance "Open Funnel" Air Filter (4.5" inlet I.D.) - Chrome Cap
And of course K&N doesn't have an Outer Wear for the Vibrant Filter's dimensions, so I'll order up a custom set.
I know a couple people who use that same filter.

I will probably order up the 4.5" Mandrel Bent Mild Steel Tubing from the same place above, because it's only $40, it's in stock, I can cut it to fit, I can paint it what ever color I choose.
My Intake temps will sometimes get over 130+ *F in the Summer here in California.
Cruising I've seen 110*F... :notgood:

I can't wait, and I've always wanted a CAI.
 
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