DIY CAI(or Do-it-yourself Cold Air Intake)

If you are here then you probably have heard of the gains that are possible by getting rid of that restrictive stock intake and adding an AEM unit instead. When I first saw the $230 AEM price tag I about fell over. I wondered how anyone could spend that much on some tubing, a filter, some clamps and a sticker. But, if you are a cheap bastard (like me) and have the tools and skill you can make your own. So here is how I made mine.
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Before you continue I am not responsible for anything that goes wrong with your car or this installation. Take your time, think things through and use common sense. Perform this modification at your own risk.
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Materials:

1 - 180� bend 2.5" mandrel bent aluminized steel tubing - JCWhitney - 81zx3035n - $23.00

3 - 2- rubber sleeves with clamps (they will stretch) - Lowe's - $4.00 ea

1 - Conical Air filter - Auto Parts Store - $20.00

1 - AN fitting (for crank case vent) - Auto Parts Store - $2.00

1 - 12" length of rubber hose - Auto Parts Store - <$1.00

2 - small hose clamps - Auto Parts Store - $1.00

1 - Barstock - Lowes - $1.00

1 - can High Temp Paint - Auto Parts Store - <$4.00
Total: $54.00
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Tools: Screwdriver
Hacksaw
Drill
Welder (optional)
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The first step in making the intake is to wash the tubing. Mine was covered in manufacturing oil and filthy

Remove the stock intake assembly and front bumper

Lay the pipe in the engine bay to get an idea of how you will cut the tube to best fit your car. I started at the throttle body and worked my way down.

In the tools list I said the welder was optional. In the places where I've welded the pipe you can just use hose clamps. I welded mine to reduce the number of clamps I would need, for a cleaner look and to make the unit more rigid. In the above pic you can see where I welded pipes together. I also ended up welding the two upper pipes (1&2) together later on because it would flex too much and come loose.

Now that you have all the pieces cut out and de-burred you need to install the AN fitting. This is a very important step. Without this fitting and the hose installed the car will not run. If you look in the pics you will not see on mine. That is because I installed mine on the backside don't ask why. I drilled a hole, used a tap to put threads in the tube, screwed in the AN fitting and sealed it with JB Weld. You don't want any air leaks.

Next, you need to make a support bracket. I found some barstock at Lowes and welded it to tube #2. The slotted end fits onto the screw that held on the stock air box.

Painting. I originally chose Silver 1200� paint. If you use this paint you must bake it in the oven to fully harden and cure it, otherwise; it will rub off and make a mess... once again, don't ask. I later decided I liked the red 500� paint better anyway.

Here is the final product in the car.

Finally, put the bumper back on and go for a drive!

The first thing I noticed was the sound. The car definitely has a more aggressive growl, especially at higher RPMs. I haven't dyno tested it yet but it sure feels stronger all the way up until redline.

Water Ingestion. I lived in Florida for a year and now in Georgia and I've had this setup installed for about a year. I've driven through puddles that are 4"-6" deep and hard rainfall. I haven't had any problems.

For a look at another CAI project check out teamsolcal.com. It's on a Del Sol but the info is great.

*Update*: I welded the two upper pipes together so the system now has only 2 pipes, painted it red and aquired an AEM sticker.

Page 1: Main
Page 2: Cold Air Intake How-to
Page 3: Cup Holder How-to
Page 4: Steering Wheel Spacer How-to
Page 5: Accident, windshield
Page 6: Re-done 1/18 Hot Wheels Tunerz CRX
Page 7: Other aircraft models I've made.
Page 8: Odd stuff
Page 10: Accident, LR 1/4 panel
Page 11: Body Shop
Page 12: Body Shop Day 2
Page 13: Body Shop Day 3
Page 14: Body Shop Day 4 & 5