2012 Focus Custom Ram Air How-To

[Some Guy From NY]

I just ordered all the necessary parts for this mod...I plan to attempt a fiberglass scoop to fill the entire space in that lower grill area.

However, How do I remove the front portion of the cover under the car? Do I need to remove the felt portion under the engine too or can I leave that on?

[dyn085]

It is probably easier for you to just pull the triangl out than to try and work from under the car. You have to slide something in between the triangle and the bumper cover to get the tabs to release, then it just pops right out. I just pushed out the block plate and then forced the triangle out, but I probably got lucky that I didn't break any of the tab holders.

Do you just plan on doing a wet lay-up or are you going to bag it? I made mine in a hurry and jisy did a lay-up, but bagging it would have finished it off better.

You will be exhaust limited after doing this. I did the dyno runs on it this weekend and couldn't pull much more power out of it in comparison to the snorkel delete. Not a bad thing, it just means that we are sitting on the same power as the name brand CAI's

[Some Guy From NY]

Originally Posted by dyn085

It is probably easier for you to just pull the triangl out than to try and work from under the car. You have to slide something in between the triangle and the bumper cover to get the tabs to release, then it just pops right out. I just pushed out the block plate and then forced the triangle out, but I probably got lucky that I didn't break any of the tab holders.

Do you just plan on doing a wet lay-up or are you going to bag it? I made mine in a hurry and jisy did a lay-up, but bagging it would have finished it off better.

You will be exhaust limited after doing this. I did the dyno runs on it this weekend and couldn't pull much more power out of it in comparison to the snorkel delete. Not a bad thing, it just means that we are sitting on the same power as the name brand CAI's

I really think I will have to work from under the car. I never used fiberglass before so I do not know what you mean by wet lay up or bagging it. What I plan to do is make a cardboard mockup of the scoop, line it with wax paper, and then apply the fiber glass using this kit: http://www.amazon.com/Fibreglass-Eve...fiberglass+kit

Do you know how to remove that cover from under the car? I rather go through that effort (and think I will have to in order to mount it the way I want) rather than mess with the triangle.

From the few videos posted here I like the sound more than the aftermarket CAIs available. I was contemplating an exhaust but looking at my options they are pretty expensive. I may just go the cheap route and get a nice sounding muffler instead of an entire system.

I have been watching a lot of fiberglass DIY videos and I am confused about how many layers I should apply. Suggestions?

[dyn085]

The difference between a wet lay up and bagging it is that when you bag it you apply a constant suction to plastic surrounding the glass/part. This helps to ensure a tight bond and proper penetration of the glass by the resin.

For taking off the bottom, there are some of the push pins and I believe a couple torx bit screws. Should be pretty easy.

If there is enough material, 3 layers is typically prefered. The first layer, one laid 90° to it,.and then one final laid at 45°. In this type of component I wouldn't be overly concerned. I did a wet lay up with two layers, one at 45°.

[Some Guy From NY]

Originally Posted by dyn085

The difference between a wet lay up and bagging it is that when you bag it you apply a constant suction to plastic surrounding the glass/part. This helps to ensure a tight bond and proper penetration of the glass by the resin.

For taking off the bottom, there are some of the push pins and I believe a couple torx bit screws. Should be pretty easy.

If there is enough material, 3 layers is typically prefered. The first layer, one laid 90° to it,.and then one final laid at 45°. In this type of component I wouldn't be overly concerned. I did a wet lay up with two layers, one at 45°.

Thanks.

This project of mine is going to be delayed a bit...I want to do it after I get my steering rack replaced...and I spoke to the dealer today who said it may take another 3 weeks to come in. Until then I am amassing the parts/tools to do this.

[dbsimms63]

Good job.

[dbsimms63]

Does anyone know about these CAI units:FOCUS 12-12nSecret Weapon Intake System - 4Cyl 2.0L? I have never heard of Secret Weapon.

[dbsimms63]

Originally Posted by immaengineer

From my experience CAI and CATback exhaust doesn't void warranty, I've done this on my past 2 cars with no problems from dealers. As long as the correct sensors are in place you should be find. Great build, change the rubber hose to a bend aluminum pipe and you'll be golden!

Would PVC be better than aluminum? No heat soak.

[dbsimms63]

Originally Posted by newmission

During some R&D today, the intake air temp balanced out at 2.5 degrees above ambient. Not bad, but I'd like to try for better at lower speeds.



So I picked up a 94 cents funnel and slapper her on. Have yet to do a run. But we'll see. Also adding more holes to the grille insert.

After reading about this mod, this was exactly what I was considering, siliconing a funnel to the end of the radiator hose and drilling one big hole, like the one in the bottom of the air box, behind the triangle. What do you think?

[dbsimms63]

Originally Posted by ChrisRyan

That's the way to go. I'm in Carrollton, do you ever get up this way Chris? Maybe you could shoot me your blue prints for the scoop, I definitely want to go this route. Barely noticeable painted black on the inside.