How To: Ram Air Duct w/ Pipercross style add on - Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum
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Old 07-28-2007, 05:57 PM   #1
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How To: Ram Air Duct w/ Pipercross style add on

Time
1-2 hours depending on experience and acess to tools

Materials and Tools

Ram Air Duct
1. sheet steel or aluminum
2. metal shears, sawzall, cut off wheel... etc
3. vice
4. 4 very small nuts and bolts
5. L bracket
6. silicon bathroom caulk
7. torch *opional*
8. bench grinder or file

Pipercross style add on
1. 3 feet of 2.5-3" tubing
2. funnel or velocity stack
3. 3" pipe clamp
4. drill
5. matching hole saw (3" pipe use a 3" hole saw)
6. small peice of sheet metal


Plans





Procedure

1. measure out and draw the given dimensions onto a peice of cardbord. these 2 peices will become your templates.

2. go to the car and remove the radiator cover. undo the screws then pop the plugs out and it the cover comes off.

3. test fit the carboard peices and mark out the places for the holes and where to bend the metal. the line on my plans that doesnt have a measurement is the line i used to judge the bend.


4. trace your templates onto your sheet metal. make sure to take note the the postion of the holes and the bend line

5. when cutting the metal it is always safer to cut a little bit bigger than your actual dimensions. you can always grind it down.

6. now clamp the cut out peice into the vice at the fold line. this is where a torch might come in handy if you are using a beefy stock of metal. but begin to bend the peice. bend it a little then check it on the car just keep going back and forth. this is also a good time to grind and perfect the fit of the duct.



7. the little triangular peice is very tricky because it is cruved in 2 dimensions. so its curved and twisted. the only real way to get this is by trial and error so be prepaired to spend alot of time going back and forth from the car to the vice.

8. at this point you should have something that resembles this but without the





9. to make the bracket i just took a L bracket and bend it to the same angle i wanted the triangular peice. drill some holes and bold them together.



10. run a beed of caulk where the 2 plates meet

11. put the now completed duct into the correct location. now go get the radiator cover and try to put it on. draw a ling on the cover where it needs to be cut, like i said before its better to be a little bigger. so cut it bigger then you can shape it perfectly





12. put everyhitng back together and YOUR DONE!




Pipercross style add on

1. remove the airbow and cut the resonator sleeve thingy off. once its cut off drill a hole with the diameter of the pipe you are using.

2. cut a small peice of metal that will fint inside the airbox that will completly cover the hole. now trace the hole you drill in the airbox onto the metal

3. drill the metal out and test fit.



4. run the pipeing down to the grill area

5. install your velocity stack of choice to the end using a hose clamp



6. ziptie to the grill

7. then seal the metal plate with more silicone caulk.

8. YOUR DONE


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Last edited by scrammer; 03-18-2008 at 08:41 AM.
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Old 07-28-2007, 06:04 PM   #2
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i have the bottom setup with it piped to the volant box hole. I love it. I do need a cone on the front though.....I should go but a funnel.....
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Old 11-12-2007, 01:58 PM   #3
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instead of chopping up your air deflector, add this!
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Old 11-12-2007, 02:35 PM   #4
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can we get that here?
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Old 11-12-2007, 02:39 PM   #5
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Nice little write up. Finished piece looks cool to. I just took my OE scoop, mounted it on the bottom of the radiator and ran ducting to the bottom of the air box.
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Old 11-14-2007, 08:56 AM   #6
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Quote:
Originally Posted by Head View Post
can we get that here?
the site to get the piece is printed on the picture.
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Old 11-14-2007, 11:08 AM   #7
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Quote:
Originally Posted by scrammer View Post
the site to get the piece is printed on the picture.
I poked around there and could not find it plus it is in the UK. I was curios if there a US supplier.

thanks
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Old 11-14-2007, 01:49 PM   #8
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CLICKY
they ship to the US
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Old 11-14-2007, 02:18 PM   #9
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if you buy a cai does that destroy the point of doing this or can it still help?
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Old 11-14-2007, 02:50 PM   #10
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this is for stock boxes. if you buy an aftermarket intake, there is no point in this mod.

UNLESS
you buy a SRI (short ram intake) this keeps the filter in its current location but it includes a conical filter and a tube to replace the intake-maf section.
then this mod will allow more fresh air to reach the SRI than from stock if you were to leave the snorkel in place.
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