Battery Box CAI

Before Box

I wanted my K&N system to be a little more of a Cold Air Intake or CAI. I had to find something that my filter would fit in but, small enough to fit the area. My first thought was a small ice chest. I thought it might be funny as a CAI. I couldn't find one that would fit right. If you can find one do it!
I started to use a 24 pack Pepsi box to help me get the dimensions I was needing. After I cut it down to the size I needed I noticed my battery being about that same size. This made me think of a battery box. Well, whaddya(sp) know it fit!!

I started by measuring the size of the adapter which, was 6" in diameter. I placed the filter inside of the box for placement and then cut the hole which, cut off the handle also.

That looked good so, I started working on the front of the box where the air comes in from the inner fender.

I decided to use a toilet flange for the the front of the battery box. I had to cut off the other handle and make it smooth for the flange. This left 2 small triangular holes in the box. It will be alright because, I used RTV to fill the holes when I attached the flange to the box.

The toilet flange went from 3" to 4". I cut a hole in the battery box that was 4" to maximize the air intake. Then I needed to cut about a 1/2" off the bottom of the flange because, it was hanging over the bottom edge of the box. Also, the holes in the flange are where I bolted it up to the box. I needed to make the 2 holes on the right bottom side flush with the inside plastic. This area is where it would rub on the cruise control box, at least on mine.

Here you can see the flange bolted up to the battery box and how I filled the small holes with RTV.

This is a shot of the box with a 3" piece of PVC pipe. There is probably a couple of different ways to do this area. Using the PVC pipe you are going to half to sand down one end to fit the oblong shape of the inner fender hole. This is 3.5" wide and 3.25" high. Or you can get some 3" corrugated/duct tubing to fit. I think its probably easier to use the 3" corrugated tubing.

Here's a couple of shots with the box in place. I still need to get the contours of the hood for the top of the battery box.

I figured out a way to get the contours of the hood using sidewalk chalk. I put the chalk on the edges of the box, bring the hood down til it stops, check where the chalk hit the hood and I would cut out that section. I did this til I had the contour cut into the box.

I also did this trick to make sure I had a seal with the weather stripping to the hood. This pic shows that.

And here it is all nice and ready to go!

Battery Box- $7
Toilet Flange- $6
3"pipe @12"- $2
Nuts and Bolts- $2
Weather Stripping- Free (Out of junk yard or body shop)Mine came off of a late 90's Blazer back hatch.
Total= $17 and a big smile!!

I do want to say that not all my measurements will be the same as yours. I do not even know if this is the correct K&N system for my truck. The connection up by the intake housing to the intake tube appears to be pinched, like when you're trying to put two straws together. Its weired, but it works.

I started this project here Battery Box CAI

If I had the original equipment intake, I would have done the Gotts Intake Mod here Gotts Intake Mod

There is another way of doing it using an office trash can. Its not as closed in as the Battery Box CAI. Here's the link.
Office Trash Can CAI

Thanks for looking!!