GT500R Posted February 18, 2018 Report Share Posted February 18, 2018 So taking a page out of Xtra's book on this thread - http://www.fordedgeforum.com/topic/22798-g2-edge-sport-cold-air-intake-hack/?hl=snorkel I decided to check this out and see what the hype is all about. So I took a look at what the current view is for fresh air to go into the air box - So the first thing you notice is the hood latch mechanism in the way.... nice Ford. So I tried moving it completely out of the way but couldn't get a good spot, but low and behold there is a lip that sinks down between the inlet and the latch mechanism. So two holes later and it was moved out of the way - Now that it was out of the way lets see how it looks - MUCH better, now that the piece is out of the way, so is the cord (right hand side). But there still is an improvement for the one piece hanging down right in the middle. Take that out and PRESTO - Now air can get into the car with no obstacles. Now the real question... so what are the gains? Well, nothing great overall... nothing you will most likely notice seat of the pants, maybe a bit less laggy but I did notice a smidge more timing up top. I notice that the intake temp in the box was down 4* F overall based on 5 average runs previously and just one run with the improved flow. Is it worth it? Well it is a free mod and does remove anything in the way of the intake, so I say it is worth it. 4 Quote Link to comment Share on other sites More sharing options...
Cree Posted February 13, 2019 Report Share Posted February 13, 2019 Nice work man. I am getting ready to do this this weekend. Looked at xtra’s great post and I like the way you gave us a view of the air flow. Now I am fully prepared. ?? 1 Quote Link to comment Share on other sites More sharing options...
Rimcrim Posted February 22, 2019 Report Share Posted February 22, 2019 I don't think this will work the same for the ST. I tried looking but the air intake is covered and not visible at all from the front or top of the vehicle, there's a black plastic piece covering the top and I think the air is taken from the grille below and then up to the air box. I'll try and post some pics next time I look. Quote Link to comment Share on other sites More sharing options...
Rimcrim Posted February 22, 2019 Report Share Posted February 22, 2019 Edit: nevermind, need to take off the front cover Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 22, 2019 Report Share Posted February 22, 2019 (edited) This is very early and I am letting the cat out of the bag and most of the time that is not a good thing ... I have started to make a mold for a new Sight Shield to increase air flow to the snorkel . I have not yet decided as to vacuum form or compost lay up. As this will take some effort to properly design and fabricate I will give updates from time to time as progress is made. At this point it is just an experiment. Edited February 22, 2019 by Xtra 3 Quote Link to comment Share on other sites More sharing options...
Cree Posted February 23, 2019 Report Share Posted February 23, 2019 I see what your doin there. Looking forward to what you come up with 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted July 11, 2019 Report Share Posted July 11, 2019 (edited) Although I posted the finished project in another thread I thought I would follow up with what I started here . This is the clay after shaping. I made sure the hood would close and used small worms of clay to check hood clearance. You can see where the closed hood smashed the worms and how much space I have left. I did this every inch across the entire form. Edited July 11, 2019 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted July 11, 2019 Report Share Posted July 11, 2019 The idea of this is to allow more volume under the sight shield for better air flow. After I covered the clay with aluminum foil and extended the edges with foam core, clear packing tape covered the entire thing as the release agent. Several layers of fiberglass cloth and mat were then applied. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted July 11, 2019 Report Share Posted July 11, 2019 (edited) Trimmed to shape and covered with bondo it is ready to sand, paint and install. Although the finish is not perfect it fits well and works with the grill mods I already have. Been using it for a couple months now and it is better than stock according to my butt Dyno .. LOL , and will continue to use it . Now all I need is a " SS intake " Thats the snmjim & Special_K intake recently developed and I will have a complete system. Edited July 11, 2019 by Xtra 1 1 Quote Link to comment Share on other sites More sharing options...
Special_K Posted July 11, 2019 Report Share Posted July 11, 2019 Looking good my man! keep it up! 1 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted July 11, 2019 Report Share Posted July 11, 2019 Oooooooooo the good ole days of 'glassin'! Nice work! 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted July 12, 2019 Report Share Posted July 12, 2019 (edited) "Necessity is the mother of invention" Edited July 13, 2019 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
IcyFridge Posted August 9, 2020 Report Share Posted August 9, 2020 On 2/18/2018 at 5:00 PM, GT500R said: So taking a page out of Xtra's book on this thread - http://www.fordedgeforum.com/topic/22798-g2-edge-sport-cold-air-intake-hack/?hl=snorkel I decided to check this out and see what the hype is all about. So I took a look at what the current view is for fresh air to go into the air box - So the first thing you notice is the hood latch mechanism in the way.... nice Ford. So I tried moving it completely out of the way but couldn't get a good spot, but low and behold there is a lip that sinks down between the inlet and the latch mechanism. So two holes later and it was moved out of the way - Now that it was out of the way lets see how it looks - MUCH better, now that the piece is out of the way, so is the cord (right hand side). But there still is an improvement for the one piece hanging down right in the middle. Take that out and PRESTO - Now air can get into the car with no obstacles. Now the real question... so what are the gains? Well, nothing great overall... nothing you will most likely notice seat of the pants, maybe a bit less laggy but I did notice a smidge more timing up top. I notice that the intake temp in the box was down 4* F overall based on 5 average runs previously and just one run with the improved flow. Is it worth it? Well it is a free mod and does remove anything in the way of the intake, so I say it is worth it. What piece was that in the middle and how did you remove it? 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted September 21, 2020 Report Share Posted September 21, 2020 (edited) I have been working on molds to make a buck for the intake I designed, and have completed a couple of attempts without success. Bubbles and uneven mixing of chemicals are a few of the problems I have encountered. I am not deterred and the third time is the charm. I learned so much on the first couple tries I have confidence in this next attempt. Mold ready to release Top of mold The molded buck has many flaws in it and it will be easier to make a new mold and recast the Buck than to try and fix this mess. Edited September 21, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted September 22, 2020 Report Share Posted September 22, 2020 Nice. It's not easy making molds lol. What material are you using? Quote Link to comment Share on other sites More sharing options...
Xtra Posted September 22, 2020 Report Share Posted September 22, 2020 (edited) Fiberglass and it is messy and smelly. I am making a buck for the air intake I designed Edited September 24, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted September 23, 2020 Report Share Posted September 23, 2020 My sincere sympathies. I had made a spoiler for my Tempo decades ago, but that was a cakewalk compared to this! 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted September 24, 2020 Report Share Posted September 24, 2020 (edited) Progress is being made, I rebuilt the mold and started casting the vacuum form buck. I believe that I have it figured out now and should have the buck out of the mold by this weekend. It is expensive, dirty work, so this will be my last attempt. Empty mold ready to go. The first critical layer is done. Edited October 7, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted September 25, 2020 Report Share Posted September 25, 2020 (edited) Added another couple of layers of glass today and it is coming along. I believe I will have a good starting point with this attempt. It will take a ton of sanding and finish work before it is ready to use. Edited September 25, 2020 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted September 28, 2020 Report Share Posted September 28, 2020 invested in some serious masks i hope! 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted September 29, 2020 Report Share Posted September 29, 2020 (edited) I finished casting the buck today.. I added hollow places So I can drill through and have vacuum to help pull in the ABS . I floated the last coat to have a flat even foot that I can finish with a little sanding. Tomorrow I will remove it from the mold. I hope that it is good enough to work with this time. If so, then I will get a good mask for all the sanding that will have to be done. ? Edited September 29, 2020 by Xtra 2 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted September 29, 2020 Report Share Posted September 29, 2020 (edited) I pulled the buck from the mold today and did a little rough finish work on it. Sanding makes a huge mess, I had to stop several times to get the dust off of me ☠️. Thank goodness for N95 masks Also, had to leave my clothes outside when I stopped sanding and went inside to clean up. I think this buck is going to work fine. The bottom sanded flat. A bit rough but, the top of the buck is ready for Bondo and finish work to smooth out any imperfections and define the lines.. Edited September 29, 2020 by Xtra 3 Quote Link to comment Share on other sites More sharing options...
Xtra Posted October 1, 2020 Report Share Posted October 1, 2020 (edited) I cut my right thumb pad while sanding today, darn fiberglass. The cut does not bother me as much as having to shelf the project for a few days while I heal up some. Edited October 7, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Timmay Posted October 1, 2020 Report Share Posted October 1, 2020 In all my past turbo car airboxes.... I just took my hole saw and swiss cheesed them. I removed weight--- maybe a couple ounces but absolutely did NOT ADD any... I will also be moving the cable as shown here to increase what little ram air effect that little slit could possibly have... 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted October 7, 2020 Report Share Posted October 7, 2020 (edited) Work has resumed, and it is starting to take shape. Edited October 7, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
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