Custom Cold Air Intake

Excerpts from the Flyin' Miata FAQ page: Cold Air Intake

"The advantage is that it sucks in cold, dense air. Cold air is denser, which means it has more oxygen.
More Oxygen = More Power."

"Open element, cone filters have a loud growl. Underhood temps, where cones pick up their air, are 40-50F above ambient air. This hot air is not doing you any favors!
Remember, loud does not equal fast... "

"The rest of the stock intake is fine for a Naturally Aspirated engine. We recommend leaving the Stock Crossover Pipe. The Resonance Chamber in the pipe improves Midrange Torque vs. aftermarket straight tubes."

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Based on this, I didn't like most Intakes I saw.
They increase Throttle Response but Lose Mid-Range Torque.
They are just Too Noisy.
They suck hot air!

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I liked the Air Box on this DDMWorks Stage 2.

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How My Design Works :

Insulates incoming Ambient Air from Engine Heat.
Exposes the most Frontal Intake Area as possible.
Directs air from the 4" aperture under DS Headlight and the side of the Radiator.
Decreasing Chamber size funnels air to the Filter Inlet.
Eliminates Intake Noise.
Retains the Stock Intake Filter System.

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How I Made It :

I made Cardboard Patterns of the side & back panels Seperately.
I taped them together at The 90* Bend to make a Single Pattern that I could lay out flat.

Next, I transferred the pattern to an old Aluminum Sign that I had.

The piece was cut out with a Jig Saw. For a smooth edge, I used a 20 tpi Metal Cutting Blade.

 

 

To form the Bends & Flanges, I used some scrap Red Oak, C-Clamps, Rubber Mallet, Small Ball-Peen Hammer and Patience to Not stress the Aluminum & crack it.

 

 

I made most of the Bends and then Trimmed where needed.

 

 

It bolts in solid. Not rubbing or vibrating anywhere.
All electronics mounted.
I waited until now to pattern the Lid, so it fits precisely.

 

 

 

To Insulate against Heat & Noise, the interior of the enclosure was sprayed with two coats of Rubberized Undercoating.

Both pieces were Sanded with 220 Grit Paper.

#8 OH Phillips Screws and CS Finish Washers to secure the Lid.

 

Ta-daaaaa... This Is IT!

I think it looks Nice & Clean.
And, It Works !

 

 

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