6.1 Hemi 69 Barracuda Fastback Father Son Project
Making progress with my DIY CAI
Laid out my cardboard Airbox model and transferred the measurements to a sheet of1/8" thick Black Textured ABS plastic.
Thought about how I wanted to make the corners and decided to create Tabs that would bend and be inside the box to attach them to the adjacent sidewalls after forming the box.
Once I was happy with the layout, I used a piece of flat bar steel as a cutting guide and to clamp down and hold my plastic as I cut it out with a Dremel plastic cutting disc. Keeping the Airbox plastic under the bar stock as a guide helped to keep my lines nice and straight and any slips would be into the waste material.
Set up here for my first cut.
Just happened to work out with the 2 longest straight pieces landed on factory edges.
Here it is all cut out.
I made a sheet bender with some scrap pieces of wood, a heat strip, some aluminum foil and some aluminum heat duct tape.
Figured out the order to make my bends without blocking any of the next bends... and started heating and bending. Here is the first bend. Then heating 3 tabs that need to fit inside the box, so these needed to shift inward a little bit. This is where there is a bit of guesswork... No directions included...
Next side...
After making all the bends and some gorilla tape to hold it together. Not too bad...
Cut a hole for the filter and test the fit. It's Good!
I'll make a shield to go in front of the filter to prevent debris coming straight through the grill into the filter.
I'll make a drain out the bottom corner nearest the fender. That corner is directly over what I think was the battery tray drain hole...
Thought about how to fasten all the tabs to the adjacent inside walls, and decided to not just glue but glue and screw.
Will use a combination of glue and fasteners to make sure it is plenty strong and durable.
Will make some standoffs and mount the box through the core support and the inner fender.
After I get the location exactly where I want it, I'll cut a hole in the Airbox for the Air inlet connection to line up with the hole in the core support. The Airbox will be connected to the core support with a short section of 4" rubber hose.
Waiting on some black Truss Head fasteners now...
Thinking about different Lid configurations, multiple versions bouncing around in my head.
ABS Flat lid with fasteners down through the lid to the box.
ABS Shoebox style lid with fasteners through the sides of the lid into the box.
Plexiglass or acrylic lid
Metal lid
ABS lid with an Acrylic window
Probably go very basic to start and then maybe change it later on down the road...
Making progress with my DIY CAI
Laid out my cardboard Airbox model and transferred the measurements to a sheet of1/8" thick Black Textured ABS plastic.
Thought about how I wanted to make the corners and decided to create Tabs that would bend and be inside the box to attach them to the adjacent sidewalls after forming the box.
Once I was happy with the layout, I used a piece of flat bar steel as a cutting guide and to clamp down and hold my plastic as I cut it out with a Dremel plastic cutting disc. Keeping the Airbox plastic under the bar stock as a guide helped to keep my lines nice and straight and any slips would be into the waste material.
Set up here for my first cut.
Here it is all cut out.
Figured out the order to make my bends without blocking any of the next bends... and started heating and bending. Here is the first bend. Then heating 3 tabs that need to fit inside the box, so these needed to shift inward a little bit. This is where there is a bit of guesswork... No directions included...
Next side...
After making all the bends and some gorilla tape to hold it together. Not too bad...
Cut a hole for the filter and test the fit. It's Good!
I'll make a shield to go in front of the filter to prevent debris coming straight through the grill into the filter.
I'll make a drain out the bottom corner nearest the fender. That corner is directly over what I think was the battery tray drain hole...
Thought about how to fasten all the tabs to the adjacent inside walls, and decided to not just glue but glue and screw.
Will use a combination of glue and fasteners to make sure it is plenty strong and durable.
Will make some standoffs and mount the box through the core support and the inner fender.
After I get the location exactly where I want it, I'll cut a hole in the Airbox for the Air inlet connection to line up with the hole in the core support. The Airbox will be connected to the core support with a short section of 4" rubber hose.
Waiting on some black Truss Head fasteners now...
Thinking about different Lid configurations, multiple versions bouncing around in my head.
ABS Flat lid with fasteners down through the lid to the box.
ABS Shoebox style lid with fasteners through the sides of the lid into the box.
Plexiglass or acrylic lid
Metal lid
ABS lid with an Acrylic window
Probably go very basic to start and then maybe change it later on down the road...