CAI setups [Archive] - VWWatercooled Australia

fuzion

19-07-2007, 02:50 PM

http://bambergvr6.50megs.com/stock_airbox_cai.htm

check that link, instructions all inclusive too. thats what ive done and prob the best ive seen

mels black gti has the AEM Intake on it which gives a very throaty sound and you can hear it suck quite loudly too (nice) as well as the dv (even stock) gives a woosh sound through it.. (getting a 2 made up soon so if u want one...)

pix of aem on car

http://www.vwwatercooled.com.au/forums/

http://www.vwwatercooled.com.au/forums/

gpk_gti

19-07-2007, 04:02 PM

yeah I did.chopped about a 5 inch round hole where stupid standard pipe connects,then sikaflexed a induction pipe into hole.must better sound and a little more power.

ope126

19-07-2007, 08:37 PM

Does anyone know where a "How To" for smoothing the OEM airbx is?
I have a K&N Panel Filter, so will not be going the pod filter route, although I would be keen for futher intake smoothness! :D

Ideas...

Glenn

gpk_gti

19-07-2007, 08:42 PM

open it up and look at the bottom,there are a few plastic fin parts,ditch them,,use a pliers,they will click off.and then with a sharp stanley style scrapper.its pretty easy and straight forward.

99gti

20-07-2007, 03:54 PM

Hmm - I might give the 3 inch hose a go this weekend...

SoVeReIgN

20-07-2007, 04:07 PM

I used a 3" hose from Autobahn/Supercheap and put it down into the front bar - Didn't make a whole lot of difference imo

fuzion

20-07-2007, 05:07 PM

I used a 3" hose from Autobahn/Supercheap and put it down into the front bar - Didn't make a whole lot of difference imo

i noticed a difference on mine from stock definately. maybe chip difference possibly?

noticed a difference with the AEM intake, but not sure if thats from sound/mental change or really did change, they are proven however so who knows!

Cache

20-07-2007, 08:50 PM

I'm also interesting in modifying mine. Keep us updated with your results!

99gti

24-07-2007, 09:52 AM

Didn't get a chance to do it on the weekend - I might try for this weekend... If I do - there will be a nice little guide with photos. Stay tuned...

balkanac

24-08-2007, 05:39 PM

sierra055

13-10-2007, 04:21 PM

Hi guys,
Just finished installing my boost gauge, and was looking to modify the standard airbox.
Is it necessary/worthwhile getting rid of all the ridges across the lid as well, or just the bottom of the airbox?

Cheers!

sierra055

13-10-2007, 05:42 PM

Oh, and how on earth do you get the pipe down under the headlight?!?!
I've got a pretty thick loom crossing right over the hole and it doesn't seem to want to move :(

ope126

13-10-2007, 05:45 PM

Oh, and how on earth do you get the pipe down under the headlight?!?!
I've got a pretty thick loom crossing right over the hole and it doesn't seem to want to move :(

I was scratching my head thinking the same thing! :?
Anyway...just smoothed the bottom of the box for now! :D

sierra055

14-10-2007, 08:04 PM

OK, so after 30 minutes of worry and a quick 15k run, here are some photo's of my interpretation of the airbox mod...

Smoothed box...
1191

Silicone hose running down the side. This stuff was great! Very strong, flexible and above all, smooth inside to stop turbulence.
1193

This took me a fair while to sort out. Basically I used a funnel, cut the end off to allow the silicone hose to pass though for a snug fit. Then, to get everything to fit I removed the horns and made up a new bracket to refit upside down and pushed out of the way.
1194

Here is the vent back in. I dremeled out the covered slats to increase airflow some more. I might give the silver there a quick spray of matt black paint to stop it from standing out too much.
1195

The view from beneath. I decided not to trim the silicone hose down and that the bend in the pipe should hopefully, in the unlikely event of water ingestion, stop it from making it's way all the way up the pipe. Note the remounted horn (I left the second one out...)
1196

Overall, the car DOES seem to have some improved throttle response but I can't say for any power improvement. Mind you this is on a stock car, so it may be too early to tell. Having said that, the intake noise is great :D

Hoping to have the car dynoed in the next week or so before I make any other changes. Then car will be getting a stage 1 clutch/flywheel setup and chip upgrade. Then re dynoed. Then installing TIP and dynoed again. Hopefully will get some good information anyway.

gpk_gti

14-10-2007, 08:06 PM

thanks guys! great thread!!!!

stickied!!!!!!!!!:D

99gti

14-10-2007, 08:14 PM

Wow, what a great phot-spread. If only I knew where my camera was to di it.

Nice work!!!!

nashan

15-10-2007, 05:34 PM

I bought a universal CAI kit and Knn pod filter from autoone and didnt think it would fit at first but now i have my suspisions. Im gonna give it a go tommorow. Might need an extra 10 inches or so of piping to get it down behind the bar though. Has anyone done a solid CAI pipe all the way to behind the bar with a pod at the end? How much am i going to have to cut away to get it to work? Its a 3 inch pipe so im hoping i dont have to get the angle grinder out! ;)

ope126

15-10-2007, 09:20 PM

sierra055, well done! Fantastic write up!

What lenght of silicon tube did you get? 1m / 1.5m?

sierra055

15-10-2007, 10:54 PM

nashan

16-10-2007, 03:02 PM

Well! Good news, I gave the uni CAI kit from autoone a go this morning and managed to get it in. Took about 1.5 hours and a lot of anger and a finger pissing blood but I got it in! Made a fairly big difference i think! Mainly with fuel economy and sound. Ill getsome photos up sometime soon. Looks good too!

99gti

16-10-2007, 03:06 PM

Thanks ope126... just thought the photo's would help someone down the track as I personally find it easier to plan these things in advance :rolleyes:

I threw out the packaging, but I'm pretty sure it was 1m? I bought it from Autobarn, after hunting everywhere for something just like it. It was made by Monza (Autotechnica) and came in black, blue and red. I think it was $25 from memory...

I'm prettu sure that's the same as mine. I wouldn't go any longer than 1m. Mine ocasionaly rears its head under the front bar so you wouldn't want it too long.

Sierra - did you relocate your horn? I can't get mine tucked into the front grill like yours because of them.

DaveMack

17-10-2007, 11:54 AM

I'm getting "Invalid Attachment" error messages for most of these pics.

Dave

nashan

17-10-2007, 11:54 AM

Hey guys, finally here at the photos of the universal CAI kit from auto one on my 03 bora 2.8l 4Motion. Only 1.5 Hours install time but a lot of anger getting it in. In other words i don't recommend doing it after a short nights sleep!

http://www.vwwatercooled.com.au/forums/images/imported/2007/10/PA171161-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2007/10/PA171149-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2007/10/PA171152-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2007/10/PA171153-1.jpg

nashan

17-10-2007, 11:56 AM

And More! Let me know if you want more details or prices.

http://www.vwwatercooled.com.au/forums/images/imported/2007/10/PA171158-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2007/10/PA171157-1.jpg

Enjoy! :D

shami

17-10-2007, 11:59 AM

Do you drive your car alot?? My only concern with this setup is driving in the wet....??

nashan

17-10-2007, 12:12 PM

Yeah drive it heaps. Its an everyday driver for me. I dont think ill have any problems with wet weather. Its still a good 45-50 cm off the ground and still protected from the wheel. I cant really see the difference with this and a cold air intake into the stock airbox. As long as i don't go through any river crossings I think ill be alright :D! Ill definately let you know if i do have problems though!

sierra055

17-10-2007, 07:45 PM

Hey Neil, pretty sure it was 1m. It sits up there pretty well, and because it's glued to the funnel, then funnel bolted to the car i doubt it's going to move.

I did have to move the horns. I ended up removing one altogether and modifying the lower horn bracket so that I could mount the horn upside down and pushed to the right (from underneath the car).
You can see the relocated horn in the last pic.
I also removed the plastic shroud from behind the drivers headlight, where the old snorkel attached, just to gain a bit more clearance.

99gti

17-10-2007, 08:24 PM

Yeah Sierra - I did the same just without the funnel. I wondering now looking at all the aftermarket CAI kits with a pod. What would the difference be if I were to remove the bok at together and mount a pod like they do. Would the robber house not insulate enough heat? I doubt the air rushing through there would get much of a chnace to heat up anymore?

Rapido

11-04-2008, 09:25 PM

I'm a tad interested as to how you managed to get rid of this as shown in the picture here..

http://www.vwwatercooled.com.au/forums/images/imported/2008/04/PA171149-2.jpg

This pipe I believe monitors the temperature of the stock intake box? or the temperature within it?
How did you guys manage to pry it off the stock airbox and if so, where did you guys attach it to? in terms of your new CAI.

Cheers

NGOLF.U

13-04-2008, 03:52 AM

i moved my horn...it sits snug in the front bar. i have driven in mega wet weather and i have had absolutely no probs at all....
http://www.vwwatercooled.com.au/forums/images/imported/2008/04/airbox-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/04/airbox2-2.jpg

tigger19

13-04-2008, 10:54 PM

i have a pod filter installed on my R32 and it made a lot of difference. The car is much more responsive and the trip comp says that its using almost a litre less fuel. dont forget to get the ECU reset after fitting somrthing like this

I put a BMC DIA into my Bora 4Motion the other week. I have been watching my fuel use and it seems about the same. Others who have added a POD filter seem to report improved economy - maybe it is because I haven't reset my ECU? Is there advantages to a having the ECU reset for naturally aspirated engine? And if I need to do this can it be done by anyone who has access to VAGCOM or do you need to see a specialist?

balkanac

14-04-2008, 02:15 PM

Nah man, just disconnect the battery for 5 to 10 min and reconnect it. Thats it.
I have installed a Neuspeed CAI and its very similar to what other people have done. Its not so loud but it looks awesome under the bonnet. I'll dig up some pics and post them later.

tigger19

15-04-2008, 03:46 PM

I wish everything was that easy:rolleyes: Did you notice a difference when you reset?

balkanac

15-04-2008, 04:21 PM

i defenetly (spelling??) did. you will notice the difference even if you dont reset it, but once you do, its even better. so yeah, i'd do it for sure

tigger19

15-04-2008, 06:19 PM

Thanks for the info.
I'm happy with the BMC DAI so far but I'll see if it gets better when I do the reset on the weekend. I ended getting it from Jim (MRJZ) who put up some pictures of it when it was for sale
http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=13783 - and the price was OK in the end too!:)

IanJ

26-05-2009, 02:34 PM

Hi,
The pics in sierras post are coming up invalid. Does anybody still have a copy they could post up?

Thanks,
Ian

MIS.18T

26-05-2009, 02:57 PM

Hi,
The pics in sierras post are coming up invalid. Does anybody still have a copy they could post up?

Thanks,
Ian

here is a real intake. http://forums.vwvortex.com/zerothread?id=4405205

IanJ

26-05-2009, 03:38 PM

here is a real intake. http://forums.vwvortex.com/zerothread?id=4405205

:-D I think thats at the other end of the extreme mods spectrum from where I'm aiming at the moment!

MIS.18T

26-05-2009, 03:44 PM

:-D I think thats at the other end of the extreme mods spectrum from where I'm aiming at the moment!

hahaha yeah thats my mk4 lol.

IanJ

26-05-2009, 03:50 PM

hahaha yeah thats my mk4 lol.

Very nice fab work. Got any links to the finished car?

MIS.18T

26-05-2009, 04:13 PM

Very nice fab work. Got any links to the finished car?

she aint done yet....

sierra055

26-05-2009, 06:14 PM

Hi,
The pics in sierras post are coming up invalid. Does anybody still have a copy they could post up?

Thanks,
Ian

That's strange, i'll re upload em.

sierra055

26-05-2009, 06:19 PM

Smoothed airbox
4500

Silicone hose running down the side. This stuff was great! Very strong, flexible and above all, smooth inside to stop turbulence.

4502

This took me a fair while to sort out. Basically I used a funnel, cut the end off to allow the silicone hose to pass though for a snug fit. Then, to get everything to fit I removed the horns and made up a new bracket to refit upside down and pushed out of the way.

4503

Here is the vent back in. I dremeled out the covered slats to increase airflow some more. I might give the silver there a quick spray of matt black paint to stop it from standing out too much.

4504

The view from beneath. I decided not to trim the silicone hose down and that the bend in the pipe should hopefully, in the unlikely event of water ingestion, stop it from making it's way all the way up the pipe. Note the remounted horn (I left the second one out...)

4505

That stainless one does look nice! maybe I should update mine :biggrin:

IanJ

26-05-2009, 08:02 PM

Thanks Sierra. Doesn't look too difficult. Any idea of the benefits?

fuzion

26-05-2009, 08:30 PM

definite cheap and effective way .. works very well!

although, i would recommend cutting a small return hole underneath incase you need to drive through heavy floods

alternatively, just let the pipe/hose flop and just sit facing downwards instead.

Manaz

26-05-2009, 10:13 PM

http://i14.photobucket.com/albums/a325/frankiG/airbox2.jpg

Just beware with a setup like that of something like the following happening...

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=29713

sierra055

28-05-2009, 07:39 PM

Just beware with a setup like that of something like the following happening...

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=29713

I think that's pretty unlucky. One of the reasons I left the bend was to make it harder for water, leaves and other crap to be sucked up. I've been through some pretty big puddles, and so far touch wood, haven't had a problem.
I was also surprised to have a pretty clean air filter when I replaced it not too long ago with a BMC one. No leaves and other crap there either.

That said, if you don't want to take that sort of risk, stick with factory, short ram pod or the BMC CDA's work pretty well.