Cheap intake for those budget conscious owners!!
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Senior Member
Joined: Sep 2001
Posts: 305
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From: Richmond, VA
Cheap intake for those budget conscious owners!!
Disclaimer: These instructions are by no means meant to produce a product that is in any way superior to those sold by our wonderful supporting vendors, but more to give those owners who cannot yet afford their products a chance to get more performance from their trucks!! 
There are constantly posts on here with people looking for ways to modify their intakes, and many people argue that a simple K&N filter and a modified air box will suffice until you can buy an aftermarket setup. Well I have figured out how to produce a reasonable intake system for less than $60.
All parts can be purchased from both your local Lowes and a auto shop that sells K&N products.
The first part that will need to be fabricated is the adapter to attach a conical style filter to the MAF. Begin by removing the factory air box and all associated parts, then you can detach the MAF from the rubber intake boot and set it aside. Make sure you save the foam gasket for use later between the MAF and the new adapter.
You will need to purchase a plastic dust hood from Lowes that is normally used to catch saw dust for dust collection systems. The one I purchased is similar to the one below and measures 14" square with a 4" opening in the center. Cost $3.37
There are constantly posts on here with people looking for ways to modify their intakes, and many people argue that a simple K&N filter and a modified air box will suffice until you can buy an aftermarket setup. Well I have figured out how to produce a reasonable intake system for less than $60.
All parts can be purchased from both your local Lowes and a auto shop that sells K&N products.
The first part that will need to be fabricated is the adapter to attach a conical style filter to the MAF. Begin by removing the factory air box and all associated parts, then you can detach the MAF from the rubber intake boot and set it aside. Make sure you save the foam gasket for use later between the MAF and the new adapter.
You will need to purchase a plastic dust hood from Lowes that is normally used to catch saw dust for dust collection systems. The one I purchased is similar to the one below and measures 14" square with a 4" opening in the center. Cost $3.37
Thread Starter
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Senior Member
Joined: Sep 2001
Posts: 305
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From: Richmond, VA
Place the MAF on the back side of this panel, line it up with the opening, trace the outside edge, and mark the hole that you will need to drill. Using your tool of choice (mine is a Dremel) cut out your adapter. After sanding the outside edges, you can then drill out the bolt holes.
The hard part of making the adapter is making room for the IAT sensor that previously mounted to the air box. I found the easiest way is to simply drill out a hole larger enough to accommodate the sensor and its retaining tabs. I inserted the sensor and sealed the opening with RTV silicone sealant. Silicone sealant will allow for "relatively" easy removal in the future if need be. Notice, in the picture below, that that I placed the sensor directly in the path of airflow.
After you have finished the adapter, you can go ahead and reinstall the MAF to the intake boot. Place the foam gasket you previously set aside between the MAF and the new adapter, and bolt them together. (I used stainless bolts that I bought at Lowes for $1)
Once the adapter is installed, you can go ahead and put on the filter. I picked up a K&N from the local Autozone (part E-1796 for $52) that I felt would provide the necessary air flow. It is over 12" long and had the necessary 4" inlet to match the new adapter. This filter has a closed end, so it may not be quite as efficient as the open ended filters used by many of the vendors. However, I will use this one until I can pick up a better filter.
I also picked up 1x36 inch strip of aluminum that I will used to fabricate a bracket to hold the intake. I will post details of that install later this week along with info on a very nice (but cheap) ram air setup to accompany the new intake.
I would suggest picking up a PSP "Outerwears" pre-filter for $20 to help preserve your filter.
This mod does not cost much more than a regular K&N panel filter. So for an hour of your time, you too can have a decent looking setup that will net you some improved performance and serious blower whine!
The hard part of making the adapter is making room for the IAT sensor that previously mounted to the air box. I found the easiest way is to simply drill out a hole larger enough to accommodate the sensor and its retaining tabs. I inserted the sensor and sealed the opening with RTV silicone sealant. Silicone sealant will allow for "relatively" easy removal in the future if need be. Notice, in the picture below, that that I placed the sensor directly in the path of airflow.
After you have finished the adapter, you can go ahead and reinstall the MAF to the intake boot. Place the foam gasket you previously set aside between the MAF and the new adapter, and bolt them together. (I used stainless bolts that I bought at Lowes for $1)
Once the adapter is installed, you can go ahead and put on the filter. I picked up a K&N from the local Autozone (part E-1796 for $52) that I felt would provide the necessary air flow. It is over 12" long and had the necessary 4" inlet to match the new adapter. This filter has a closed end, so it may not be quite as efficient as the open ended filters used by many of the vendors. However, I will use this one until I can pick up a better filter.
I also picked up 1x36 inch strip of aluminum that I will used to fabricate a bracket to hold the intake. I will post details of that install later this week along with info on a very nice (but cheap) ram air setup to accompany the new intake.
I would suggest picking up a PSP "Outerwears" pre-filter for $20 to help preserve your filter.
This mod does not cost much more than a regular K&N panel filter. So for an hour of your time, you too can have a decent looking setup that will net you some improved performance and serious blower whine!
Accidentally double posted
...JR
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Joined: Oct 1999
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