04'- 05', 20 minute Intake mod!

[NMansfield]

I cut a piece of 16ga polished stainless sheet metal 16 1/8L"x8"W and rolled it to make a tube 5 1/16" O. D. x8"L, tig welded the seam on the INSIDE and OUTSIDE smoothed down the seam with a belt sander, rolled it again to make sure it was concentric. I cut two pieces if 1/8"dia. stainless filler wire 16 3/4"L. Now the hard part; with the tube in a vise I tacked one end of the wire on the top of the tube, with the wire still cherry red I bent it around until I felt resistance, tacked again, bent, tacked, bent etc... because I cut the wire too long I had to trim the end of the wire before joining the ends together. With a ring made around the end of the tube I welded it solid, then used the same procedure on the other end of the tube. I'm a professional welder with ALOT of patience, this thing was like welding paper and took some time to make but it was a good challenge with great results when installed on my 04. 5. I'll be glad to assist anyone wanting to try this themselves... Good Luck!!!

 

[ReevesRacing]

I used two 4" 90 degree rubber elbows from www.turbonetics.com and a short piece of 4" exhaust tubing to join them. This got rid of all the factory stuff from the airbox to the turbo. Nice sound and it's smooth and all the same size, instead of going from 4" to over 5" then back to 4" again.

 

[hasselbach]

you guys that are removing the inner vanes are doing nothing for airflow. I've confirmed it on a flow bench. reason? the inlet and outlet is 4 inches, yet it opens up to 5 inches in the center. when the air hits this bigger area, it slows and tumbles, causing turbulance. then at the other end of the tube, the slow air has to speed up again and hits the squared off corners necking down to 4 inches again. you are actually making it flow worse. solution? open up both end to about 4. 125 and insert a piece of 4 inch ABS piping. it will be held inplace by the end rubber caps. net effect is the air is smooth through the entire tube. the way that you are doing it now, you are killing losing about 15% in total airflow measured at 2 inches vacuum.



good luck. .

 

[Kennywould]

you guys that are removing the inner vanes are doing nothing for airflow. I've confirmed it on a flow bench.

Interesting data here. Question? I would like to know what is the airflow doing with the vane insert left in, thats what I had a problem with in my mind, I really think there is a problem there with the airflow! I will take serious consideration to the 4" insert, makes sense to me! Thanks!

 

[jnelson]

I was told by a guy at the diesel performance in clevelend TX that the air flow increases by 200CFM by removing the vanes.



I got mine out today and the turo wine with the Quadzilla intake and the silencer ring removed sounds Tony the Tiger Grrrrrrrrrrrrrrrrreattttt!!!!!!!!!!!!!

 

[vortex]

will this mod work on a 2003 305-555?

 

[ReevesRacing]

Yes, it will work on the 03's as well. It is the 2nd thing I did to modify my 03 truck! (First thing was muffler removal). Also ditched the silencer ring at the same time. Now I have an 05 and it has extra air redirectors in it after the vanes. That will all be gone when I install my 4" pipe from my 03.

 

[Kennywould]

Yes, it will work on the 03's as well. It is the 2nd thing I did to modify my 03 truck! (First thing was muffler removal). Also ditched the silencer ring at the same time. Now I have an 05 and it has extra air redirectors in it after the vanes. That will all be gone when I install my 4" pipe from my 03.

I didn't know about the 03', my biggest concern was what the rings and vanes were doing to the airflow in that downtube! Maybe there is a rocket scientist out there that can explain it to me, but all I can see is a restriction to the airflow. Like yourself, I also canned the stock muffler on and intake on my 04', easy in, easy out! Your right, there are some vanes right before the turbo to help straighten the air on my 05' also, I don't remember seeing any on the 04'. It might pay to design some straight vanes in that 5" tube to help straighten the air also!

 

[Yo Hoot]

Maybe could use a can from chunky soup. Would look cool with the soup label still on :-laf

 

[bcpalmer]

Try here for an eliminator pipe: http://www.genosgarage.com/CoastalData/showdetl.cfm?&DID=30&Product_ID=1252&CATID=1

 

[Kennywould]

Maybe could use a can from chunky soup. Would look cool with the soup label still on :-laf

There you go! I'm thinking soup for dinner tonite Then a trip to the garage! Shoot! I think I have an idea for some exhaust tips! :-laf :-laf :-laf

 

[ReevesRacing]

I have a vane eliminator pipe I made out of aluminum round stock on a lathe. It's 6061-T6 and has been tumble polished, althought it could use some hand polishing now to make it super shiny again. PM me if anyone is interested in buying it.

 

[LowellR]

home depot fix...

i just bought an 03 friday to replace my 98. 5. i will eventually go the bhaf like i did on my 98 but had to do something in the meantime. went to home depot and bought a 4 inch black pvc coupling. the heavy wall one has a 5 inch od. its only about 6 inches long but the rubber elbows will stretch. $2 in parts, pop out the silencer and now i can hear my turbo.

 

[Yo Hoot]

i just bought an 03 friday to replace my 98. 5. i will eventually go the bhaf like i did on my 98 but had to do something in the meantime. went to home depot and bought a 4 inch black pvc coupling. the heavy wall one has a 5 inch od. its only about 6 inches long but the rubber elbows will stretch. $2 in parts, pop out the silencer and now i can hear my turbo.

That'll work. Just make sure the thing doesn't slip apart on you and you get unfiltered air.