Xtra

The OEM mounts need to be trimmed in order for the air box to sit low enough for the snorkel to line up. Here are the trimmed mounts, I place tape over the holes and fill them up from the backside with that same messy black RTV.

All that is needed is for the patch to be molded and installed then the bottom half will be ready for the heat shield. Getting very close, permanently installing the snorkel plate was a major milestone. For those of you that are still following the bottom half is from a 2018 to 2020 F150 EB.

I finally got the heat gun and It works great, I can now heat up the ABS and bend it to shape. Harbor Freight to the rescue. I like that this heat gun sits up and has a cool down mode. The heat gun allowed me to bend the tab on the snorkel plate to help seal and attach it. The snorkel plate is now permanently attached to the bottom half with rivets. I used black RTV to create a gasket and air tight seal. That RTV made quite a mess, but it will never be seen. Once the bottom half is fully assembled it will be wrapped with a heat shield to help protect it from excessive engine compartment temps.

That is an amazing amount of power, congratulations, you are way over 600 hp at the crank. In fact, the stock Sport has 315HP at the crank and you have doubled that and then some .. I noticed that the dyno in the photo is FWD. Did you disconnect the rear wheels some how? Without a doubt you have the worlds fastest Edge, and I see a 11 second pass and another world record in your future.

Now that all the parts have been cut and trimmed, I did a test fit and added a bolt to hold the snorkel in place. It is just taped together, and I am still waiting on the patch to be molded. I also need a heat gun to fold a flap on the snorkel adaptor plate. You can see the part of the adaptor plate that needs bending, it is sticking out under the bolt on the snorkel, it needs to wrap under the bottom edge. Right now I am using a cad plated nut as a spacer. The bolt may not even be necessary as the snorkel is a press fit into the gasket. If I decide to keep the bolt I will install a proper spacer on future V3s. This is the inside of the bottom half with the snorkel bolt installed. You can also see that the patch is in place and how it fits. The patch is the damaged one that is just being used for this test fitting. Everything is coming along and I need the new patch to be molded. When I get the patch and the heat gun It will be ready for final assembly. Once this First V3 is complete and installed, I will dyno test to see how much it helps. I have not given up, and will continue to work towards creating a high flow Air Box and filter system for the Edge platform. If the dyno results are positive, the intake air temp drops, and there are no problems found when road testing. I will to look into designing and casting my own lid. Something that would be compatible with My Adaptor and My Bottom Half ... My Lid LOL sounds like the pillow dude.

Just ordered up the Carbon Fiber material to do another run. Good news is the vendor felt so bad about the long turnaround last time that they promised to get the CF made in a timely fashion . I think that they know that they screwed up and want to make it right. If you are interested in a CF V2 then you should reserve yours now as I only ordered enough for 5. The next run will consist of 4 ABS and 5 CF intakes.

It is a good thing that I always mold a few extra intakes when I do a run, as the last CF intake of the batch just shipped and will go out on Tuesday because Monday is a holiday. It takes a long time to have the CF material made so I am going to order it now in hopes that it will arrive in 8 weeks or so in time for one more run before Christmas. I only order enough material to make 4 or 5 CF intakes at a time, so if you are interested in a CF intake this year, please reserve yours now . There is still one ABS intake available from this last batch, and the ABS material is always in stock.

Smart choice of upgrades., well done.

The last step is to cut the bottom out . There is not much left of the original. This is ready for the patch and final assembly.

The next step is to cut off this big mounting flang , it is not needed and takes up valuable space in the engine compartment. Here the flange is cut off. This is the finished side all cleaned up. No trace of that huge mounting flange.

LOL you caught me before I could finish the post

Now that the design is settled I decided to take a new bottom half and convert it into the first real non prototype V3 bottom half. Here is how I did it. This is the OEM bottom half that I start with. It has an appointment with my hand held air saw. The flange and bolt standoff for the snorkel need to be removed so there is a flat surface to work with. Cut off the flange and still needs some finish work, and the hole needs to be modified to fit the Edge snorkel . This is the finished side ready for the snorkel adaptor plate. Adaptor plate is ready to mount.then this side is done.

Thought I would give a step by step to make this happen. Do the list in order, do not order the filter first, make sure you have the Top Half Lid first . 1. Call Cobb and get the top half or lid and gasket. You only need the lid and gasket from this kit that Cobb offers. Ask for a replacement lid for your F150 or Raptor. The lid is from one of any of these kits, pick one that fits "your truck". Remember you have this kit installed and need a replacement lid and gasket. Costs around $55 A. https://www.cobbtuning.com/products/air-induction/ford-intake-system-f-150-ecoboost-raptor-limited-3-5l ... Raptor with 3.5L EB B, https://www.cobbtuning.com/products/air-induction/ford-intake-system-f-150-2-7l-ecoboost-2018-2020 ... F150 with 2.7L EB 2. Once you have the lid and gasket go online at Cobb and order a filter. The filter can be ordered on line , you don't have to talk to anyone. The filters available in wet or dry it costs around $65 + tax. A. Dry air filter, disposable will not contaminate sensors : https://www.cobbtuning.com/products/air-induction/ford-air-filter-dry-media-f-150-ecoboost-raptor-limited-3-5l-2-7l B. Oiled Air filter washable Better air flow than the dry filter, https://www.cobbtuning.com/products/air-induction/ford-intake-replacement-filter-f-150-ecoboost-raptor-limited-3-5l-2-7l C. Optional Air filter sock fits both dry and wet filter https://www.cobbtuning.com/products/air-induction/ford-intake-air-filter-sock-f-150-ecoboost-raptor-limited-3-5l-2-7l 3. Contact me ( PM ) and I will build you the bottom half and supply everything you need to finish the Air Box once you have the lid and gasket. I will do all the work except installing the sensor. I will supply the sensor and the mount, but you will have to drill a hole in the lid and mount the sensor. . I will include instructions, and it is easy to do. ** I don't have a locked in price yet on the kit but look for it to be around $420 + shipping.

Welcome back S_K Thanks for checking in.

Just because there has been a set back I am still moving forward in hopes that some will be able to obtain the lid on their own, or I find another source or way . . This is the patch that will relocate the snorkel input into the air box. This shows the gasket installed and the patch is almost ready to attach permanently.

Thank you everyone for all the positive feedback, I do appreciate the props. I am honored and grateful.

The V2 intake is still available and in stock. PM me if you are interested.

I took the rebuilt Patch mold to the plastic shop today . If it works they will make 5 patches to get started. They are also going to try to use a thicker material on the Adaptor. They think that 3/16 might do the job, but are not sure how well it will conform to the mold. Although this has been a set back, it is not the end of the V3. At the start of this thread I said that all would be posted the wins and the losses. It is all part of the journey. I just wish that I could find the Elbows at a better price, those elbows are the most expensive part of the kit.

The top half is not made by Ford. I will give the information on where to get the lid and filter here on this thread. But yes, you will have to get the top half and the filter on your own and I will supply the rest. I am a bit concerned that the vendor may catch on if all of a sudden 20 people call and order a lid in one week. It is better to have the lid in hand before getting a kit.

I have decided to go ahead and give the vendor and parts numbers for the lid and filter. I am concerned that if the vendor knows that you are not replacing a damaged lid then they won’t sell you one. They were adamant that they don’t support the Edge. I told them I had their kit on my F150 and I needed a replacement lid . The lid is part of a kit for the F150 Raptor with 3.5L EB and F150 with 2.7 or 3-5 EcoBoost . So you own a F150 with their intake installed between the years 2018. and 2020 and you need to get a replacement lid and gasket. Have a reason why if they ask ( scratch , broke, stuffed... ) If you say it is for an Edge I don’t think they will sell you one. The lid and gasket costs around $55 to $60 as I remember. A great price. The filter can be ordered on line and it comes in wet or dry from the same vendor it costs around $65 + tax. Dry air filter, disposable will not contaminate sensors : https://www.cobbtuning.com/products/air-induction/ford-air-filter-dry-media-f-150-ecoboost-raptor-limited-3-5l-2-7l Oiled Air filter washable Better air flow than the dry filter, https://www.cobbtuning.com/products/air-induction/ford-intake-replacement-filter-f-150-ecoboost-raptor-limited-3-5l-2-7l Air filter sock fits both dry and wet filter https://www.cobbtuning.com/products/air-induction/ford-intake-air-filter-sock-f-150-ecoboost-raptor-limited-3-5l-2-7l The lid is from one of any of these kits, pick one that fits "your truck". Remember you have this kit installed and need a replacement lid and gasket. A. https://www.cobbtuning.com/products/air-induction/ford-intake-system-f-150-ecoboost-raptor-limited-3-5l ... Raptor with 3.5L EB B, https://www.cobbtuning.com/products/air-induction/ford-intake-system-f-150-2-7l-ecoboost-2018-2020 ... F150 with 2.7L EB ** The two parts ( lid and Filter) will cost around $130 the kit price has not been set yet I am guessing that it will be between $350 and $420 I will try to get a hard number in the next few days. ****** Don't even ask for the Redline Carbon Fiber lid. That is only sold as part of a a complete kit> guess if you wanted the CF bad enough you could get the complete kit and only use the lid.

The filter is too large to fit in the OEM lid.

I just finished putting a finish coat on the new wood base for the Patch mold just in case the kit idea takes off . I need to make a good patch part for mine anyway, even if the kit idea flops. I added 3/4 inch plywood all around to increase the base size. That way there is more plastic available to cover the mold. If it is not enough I will have to rebuild the wood base from scratch .

I was thinking that because the Vendor would not sell me in bulk the parts needed, perhaps if you could source the parts I could complete the intake for you with a kit or something ???? The thing about the kit is, you don't have to order it until you have procured the top half. They will sell the filter to anyone, but to get the lid ( Top Half) & gasket you have to call and ask someone !! Tell them your lid was scratched or cracked or crushed in the garage by accident and you need a replacement.. lol Once you have the lid & gasket you can order the filter online, then contact me for a kit. . I know this kit will fit 2015 to 2018 Edge Sport . It might even fit the ST , but at this time I cannot guarantee this. If anyone with an ST wants to try, I will gave a full refund for the kit if it does not fit, once the parts are returned. The parts kit would look something like this and include: 1. The complete modded bottom half with heat shield, ready to go . 2. Temp sensor mount that you would have to attach to the top half. This is done with a small drill hole saw and two small mounting holes. Then pop rivets or machine screws with nylox nuts to hold it, seal with RTV . 3. Two mandrel bent 6061 aluminum Elbow reducers. These connect the filter to the car. 4. Instructions. 5. Anything else needs to complete the install that I forgot on this list. If you like the kit idea let me know . If you have an idea on how to keep the V3 alive please speak up. l am open to suggestion.

Thinking about it, I can still get the filters, and I have the elbow reducers sorted out. I would have to make an entirely new Air Box and not use any over the shelf parts except for the filter. This is a huge setback. Almost back to square one. Ironic, if this project does continue it would be the third version that would make it into production, hence ... V3. Man, this took the wind out of my sails. So close, yet so far. I have invested in development costs and countless hours of work.

I think everyone that has been following this thread knows how hard I have worked to complete this project. Today I attempted to purchase 10 top half and 10 filters to get set for production, a sizable investment of around $1, 500. They would not sell me the parts I need !!!! They said it is not their business model to do that.!!! Makes me sick all that work, and blocked by big business. Not sure what to do next.