Focus Fanatics Forum banner

1 - 20 of 427 Posts

·
Registered
Joined
·
534 Posts
Discussion Starter #1 (Edited by Moderator)
I've always been the type to have pride in the fact that I do my own work. And with that sometimes comes a better product. I knew I wanted an intake on my new Focus. I wanted a K&N filter. And I wanted it to be functional without being too "ricey", or have too much over-powering intake noise. So this is what I have been dreaming about the last few months.

Start by jumping on the net, or head to your local auto parts store, and order Gates part #22274. What you get is a 3" inside diameter, right angle heater hose. With very little trimming, it becomes the perfect fit! It runs about $37. I found mine for $23 on Amazon shipped!



While you're waiting for that to come in. Remove your airbox, along with the resonator you'll find under it bolted to the frame. I find it easiest to keep the MAF sensor attached to the box, and remove the hose clamp and wire harness to the MAF sensor.

Remove the front air dam plate by pushing it out back towards the engine bay. You can take your time to push each snap out of the way. Or just use a little extra force and it pops right out. I found this best. :)

I laid out a line across the center of each opening, and spaced out each hole I wanted to drill. Then over to drill the holes.



Finished. Of course you can drill your holes any way you like. I was going for a clean, not too obvious look while maintaining good airflow.



This is the area you want to run the hose through. It's a tight squeeze, so it will take some suggesting.



Should look like this once it's in place. Note, at this time the hose is uncut. What a nice fit eh! :)



Here's one of what she looks like from the top. (uncut)



From the first hose picture you'll notice it runs on a bit of an angle to the right. Measure back 2 inches, and cut a notch to act as a scoop. I used just a simple straight razor blade.



Here's a fun part. Remember that factory airbox we removed? Yeah well to buy one new it runs about $130. But that's ok, cause in a couple years people will be throwing them away when they buy their CAI. So you'll be able to pick on up down the road if you want to go back. But today we're going to drill a 3 1/2" hole in it! :) Get out your 3 1/2" hole saw, and cut a hole as close to the old resonator hole as possible. Always clean up your cut edges too! :)



Now put the box back in, and fully seat it in place. You want to adjust the hose so it feels relaxed. Then mark a line around the hose about a 1/4" from the bottom of the box. Remove the box, and cut the marked line.



After the hose is all cut. Reinstall your freshly drilled air dam plate, and then reinstall the hose. It may take a couple times of replacing the airbox to get the hose in the relaxed state again so you can make your bracket. I used 3/4" by 1/8" aluminum bar I get from the hardware store. While you're at the hardware store, pick up a nice stainless steel 3" hose clamp! My clamp looked like this when I was done. Depending on how you drilled your 3 1/2" hole in your airbox, yours may look different. You're going to use the hole that the resonator was using.



Now bolt your bracket in place, and install your hose clamp. BEAUTIFUL! Nice work! You're almost done!



Put your airbox back in, and adjust your hose to fit snugly in place.



Put your air filter back in, and bolt the air box cover back on. I chose to use a Outerwears pre-filter with this setup to prevent any water from getting in the engine. It also keeps bugs out of your pleats. Start her up and enjoy! Maybe roll her out on the driveway and give her a wash, cause you know you're going to want to go for a drive. :)



A little custom vinyl work to show off the Griffin Ram Air mod. :)



Now I know everyone is going to ask HOW DOES IT SOUND?!?!?! CLEAN! Not ricey at all! Not even as aggressive as a regular CAI. It has a very mellow throaty growl to it at WOT. However, which I like, it doesn't over power the engine note with LOUD intake noise. If you like LOUD intake noise, this won't cut it. If you like to hear your engine and intake compliment each other, this is it baby!

Audio: http://youtu.be/bh2LVJJNXQg

Also, I can hear people already complaining about dirt and water, etc etc. Easy fix. Of which I don't have pictured because it is still on order in the mail. Outerwears Pre-filters! With hydrophobic water shield. Either have one custom made for your filter, or hop on eBay and pick up one for an ATV and just slap it on the top side of your hose before it enters the box. I'll post pictures when I get mine in. And what about puddles and hydro-lock and all that CAI intake worries.... You're in luck. By leaving your existing factory pipes, they will act as your vacuum bypass. Aren't you smart! All your friends are going to love you! ;)
 

·
Registered
Joined
·
90 Posts
People always ask "how does water not get in your engine?"

Well it just doesn't :)
So if I don't have a problem with water running down my shaker, I'm sure you won't have an issue of water traveling uphill in yours. Looks good
 

·
Registered
Joined
·
163 Posts
That is some great work! Thanks for sharing!
 

·
Registered
Joined
·
104 Posts
Is it a factory cone air filter on these?

If not, then I'm failing to see how a drop in air filter will do any good after the mod.
 

·
Registered
Joined
·
533 Posts
Hi, I dunno but to me it is alot of work for little gain, maybe some more noise, and a invalid engine warrenty. However if you like it then fine, beauty as they say...
Chris
 

·
Registered
Joined
·
534 Posts
Discussion Starter #10
Thanks y'all!


Hi, I dunno but to me it is alot of work for little gain, maybe some more noise, and a invalid engine warrenty. However if you like it then fine, beauty as they say...
Chris
How does the SVT box and snorkel add any gains? This is a typical Ram Air set up. I don't have a way to test air flow. But with any CAI you're still SUCKING through that long tube. I don't see better gains with those things other than a temperature drop. Here you get both. But hey. It is what it is! I'm not here to argue. :)

However I was wondering about factory warranty, and how far one can go before it's void. Doesn't one void warranty with a CAI?
 

·
Registered
Joined
·
533 Posts
Thanks y'all!




How does the SVT box and snorkel add any gains? This is a typical Ram Air set up. I don't have a way to test air flow. But with any CAI you're still SUCKING through that long tube. I don't see better gains with those things other than a temperature drop. Here you get both. But hey. It is what it is! I'm not here to argue. :)

However I was wondering about factory warranty, and how far one can go before it's void. Doesn't one void warranty with a CAI?
Hi, apologies but I think we are both saying the same, I was using the usual english politeness in regards to any gains. In reality there might be losses.
Chris
 

·
Registered
Joined
·
93 Posts
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!
 

·
Registered
Joined
·
117 Posts
To void your warranty Ford would need to prove that your modification caused the damage you are having the vehicle serviced for. Even then, the warranty isn't voided, it just won't cover damage caused by modifications you made...it'll still cover other issues with the car.
 

·
Registered
Joined
·
93 Posts
To void your warranty Ford would need to prove that your modification caused the damage you are having the vehicle serviced for. Even then, the warranty isn't voided, it just won't cover damage caused by modifications you made...it'll still cover other issues with the car.
Exactly, So if you have a CAI and your MAF sensor has a problem, That part may be subject to not being covered, but they can't void your whole warranty based on it.

Basically mods are taboo now-a-days, Ford company pays to fix your car under warranty, not the dealer. If anything, they WANT to fix stuff under warranty because payment is guaranteed.
 

·
Registered
Joined
·
534 Posts
Discussion Starter #15
Good call gentlemen.

I was at first looking around for an aluminum intake pipe, but price was the same if not higher. However the real deciding factor was the allotted room. The pass through from engine compartment, to front bumper is not a perfect circle. This means I would have had to go down in size of tube diameter. Plus you are passing by the radiator. I didn't want to heat the tubing bringing in cool air. And finally the over all look. A polished aluminum tube would look out of place. The heater hose blends into it's surroundings. This way it looks like a high end system, and maintains the benefit of the larger diameter piping.

So far I'm up 1.5 mpg on the first tank, and still have yet to receive my K&N filter and Outerwears prefilter. NO CEL either! I am however getting the traction control light coming on from spinning the tires! [driving] NOTE: I'm not stating this mod somehow gained a ton of hp. But the engine does seem much happier, as does my foot. [hihi])
 

·
Registered
Joined
·
3,365 Posts
Great job. But you might have induced a problem. You need to look at your MAF counts. Your MAF should produce a smooth line. I found that blowing directly on the filter caused the MAF to produce a 'spiky' output. The fix is to put a shield over the inlet so that the air flows up and around the filter (I have a similair setup on my 07).
Use of the rubber hose is genius. Even if you have a small constriction, the rubber will produce a smooth transition. Might try and find some pieces for mine.
Add >> Oh! just noticed. Your trim piece you drilled holes in. You did not drill near enough holes for any appreciable air flow. If you take the diameter of all the hoses within 1/2 inch of the tube, and compare to the flow of a 3" I.D tube, you get a true flow picture. It's amazing how restrictive even small hole punched metal is. However, As it appears you shaped the end section (the scoop as you called it), then actually, your pulling air from behind the bumper. That may be a low pressure area due to the design of your front facia, but may negate need for the diffusser. These are all just fine tweaks. Nice job overall!!!
 

·
Registered
Joined
·
534 Posts
Discussion Starter #18
Great job. But you might have induced a problem. You need to look at your MAF counts. Your MAF should produce a smooth line. I found that blowing directly on the filter caused the MAF to produce a 'spiky' output. The fix is to put a shield over the inlet so that the air flows up and around the filter (I have a similair setup on my 07).
Use of the rubber hose is genius. Even if you have a small constriction, the rubber will produce a smooth transition. Might try and find some pieces for mine.
Add >> Oh! just noticed. Your trim piece you drilled holes in. You did not drill near enough holes for any appreciable air flow. If you take the diameter of all the hoses within 1/2 inch of the tube, and compare to the flow of a 3" I.D tube, you get a true flow picture. It's amazing how restrictive even small hole punched metal is. However, As it appears you shaped the end section (the scoop as you called it), then actually, your pulling air from behind the bumper. That may be a low pressure area due to the design of your front facia, but may negate need for the diffusser. These are all just fine tweaks. Nice job overall!!!
Thanks for the suggestions! :)

All of what you noted here was considered before making the venture. The factory inlet to the box blows directly on the filter so I don't see there being a problem with that. Also the air has to travel at a 90 degree angle once inside of the filter to reach the throttle body. At that point it's sucking what it needs to anyway.

The "scoop" cut only extends to the outer most edge of the drilled section. Not from behind the bumper. You can see the end of the hose is directly in line with the end of the triangular cut out.

However I do agree the holes could be doubled. And just may down the road. But I didn't want to open that area too much as it appears the ECU is mounted to that fender well. I also didn't want it to be too obvious and take away from the front end's over all look.

So far I am very happy with this set-up. Just received and installed my K&N last night, and ordered up the Outerwears Pre-filter a second ago. They have to be custom made. If anyone else is interested in a pre-filter, which is great in general to keep junk out of the pleats, let me know and I'll hook you up with the salesperson that has the specs.
 

·
Registered
Joined
·
3,365 Posts
Thanks for the suggestions! :)

The factory inlet to the box blows directly on the filter so I don't see there being a problem with that.
Good then. Mine actually comes in behind the filter (air making a 180 bend, about 6 inches below the actual intake of the Steeda SRI). I was just suprised by the spikes. I small deflector (air spreader) cured it.


I also didn't want it to be too obvious and take away from the front end's over all look.
Agree! Conservative changes are generally best when there visible (Note: does not apply to me. I have no taste!). I am going to have to hunt down some rubber pipe now. That just makes so much sense! [driving]

P.S. Nice bracket work there!
 
1 - 20 of 427 Posts
Top