2nd Gen Non-Engine/Transmission Factory Airbox Destroyed

[Ncostello]

As usual with my luck the most simple of things has turned into a big deal. I decided to give the old factory airbox a try with an AFE drop in filter. I now have a Fleetguard BHAF but would like to try something a little more waterproof. I'm always afraid of water getting on the BHAF during some heavy downpours and also when I pop the hood. Beaded up water seems to splash on it a little.



Anyway, I know the factory air box needs a little help in the flow department so I decided to leave the plastic fender tube off and cut the air opening larger with a dremel. I was also going to cut a triangular hole in the back side of the bottom section with the dremel.



But... first I decided to drill 5 one inch holes in the bottom with a hole saw. The first four went fine as I figured they would. The last one caused me a little problem. Just before the saw cut all the way through it "grabbed" the plastic and completely ripped it out of my hands. Now the bottom is busted out of the box in three pieces and I have no more mounting holes intact. I just sat there looking at it wondering what in the world just happened. It happened so quick I didn't have any warning the drill was going to bind. Maybe I should have let the holes go. I guess I didn't realize the plastic was so brittle. No give whatsoever.



What are you using for a drill bit on these things? Is a hole saw the wrong tool. Guess next time I'll use a dremel with a hole cutting bit. Or maybe an old butter knife heated red hot with a propane torch would work. I cant afford to make this same mistake twice.

 

[Rams-n-Hogs]

When I did mine, the first hole I drilled, cracked the housing. I used a hole saw. After that, I just let the drill do the work, no weight, no pushing on it, and I went slow. No more problems after that. Then I bought an AFE mega-cannon. It never ends.



Jim

 

[Udaloy]

If you go to use the hole saw again, try a trick the upholstry peole use, and run the drill in reverse. It has a lot less bite (obviously) and won't get out of control. I've never done it but it's worth a try.

 

[gitchesum]

I've got an airbox you can have if you want it. I ain't got a use for it now.

PM me if you want it.

 

[Dane]

What are you using for a drill bit on these things?

Hole saw and JB Weld No kidding...

 

[gregdoerfler]

just some useful info running the hole saw backwards works good on stuff you don't want to crack or chip i do it all the time on fiberglass showers when i install recessed lights in them.

 

[SEmerson]

The bhaf is geat compared to a stock box. Even cut out. Some water on it won't bother. In fact may tractor pull diesels inject water in the intake.

 

[Cooker]

To make the BHAF water proof you could add a Outerwears prefilter. They cost about $30. Just a thought.



http://www.outerwearsracing.com/frames.htm

 

[ToolManTimTaylor]

Yeah but the issue is that a wet filter media on the BHAF can in fact seperate from its media frame when it gets wet and peel away and go into the turbo ..... Then things get ugly.

 

[Oil Burner]

I've got an outerwears cover on my napa 2790 and love it. no water problems and great flow. I think it is definately worth the money if you want to keep the BHAF.

-Jason

 

[Ryan]

My factory airbox is setting on a shelf in the garage. I has already been attacked by a hole saw. I am a little closer than gitchesum, so shipping could probably be avoided if you are interested.



Ryan