Cold Air Intake

[jwintersteller]

So I finally finished building my custom cold air intake kit. I have the 6.0 PSD and I have already modified the exhaust. So this was the last step in increasing the air flow.
I was not impressed with the kit that Zylstra offered for the price. And I thought that there could be some engine heat pulled into the intake, as their kit is more a heat shield then an air-box.

The first thing I did was make the intake pipe that would house the airflow sensor. Here is a pic of the practice piece and the actual part before the sensor bracket was installed.






Next step was to built a prototype air box. This took many attempts but finally came up with this model of a 2 piece box (not counting the top). This is the only way to get the box into the engine compartment. I really wanted to maximize the size of the air box so I had to contour around many angles and the coolant tank.




I then went to work with the aluminum. Having already done all the fitting, it was just a matter of replicating the model. I am lucky enough to have access to a high school metal shop class. Where shears, breaks and TIG welder are available. The curve/cupped piece was done the old fashion way, with a hammer and a sand bag.










With just a few tweaks here and there, it went in just as I hoped it would.











I wanted to open up the stock air intake hole behind the headlamp. Here you can see the before and after.





The last thing to do was to make a top. I fashioned this out of a thinner piece of aluminum, planning on some day making something more stout, maybe something with a window so I can easily see if the filter needs to be cleaned.





We're leaving for Utah on Monday so an 1,100 mile test drive will give me a good opportunity to notice any difference.

Cheers,
John

[rockbender]

That is a work of art - looks absolutely fantastic.

I hope you see some positive results!

[BroncoHauler]

Agree that it's a work of art.

Where are you headed to in Utah? We're currently in the mid-state region, and not only has it been hot, the winds have been relentless. We're headed further south on Sunday, and then Bryce Canyon on Tuesday.


Herb

[JoeH]

Wow. Nice work! I'm going to have to go revisit your exhaust mod. As I recall there was some similar fabrication. I'm curious how much it lowered your EGTs?

We're heading to southern Utah in a week to hit Thunder Mtn and L. Creek. Then on up to Ogden for July 4th. Happy trails!

[Pschitt]

Really nice work you've done here

[carringb]

Is in the inner cross-section of your new MAF-sensor duct the same as stock? The MAF only measures flow, but the computer calculates volume based on the cross-section of the MAF-duct. Increasing the diameter of that duct will cause air velocity to slow, and the PCM will reduce fuel delivery.

DiabloSport makes a device called the "MAFia" which allows you to calibrate the MAF signal for modified duct diameters.

[PatO]

A quick look around didn't find me any aftermarket CARB compliant DIY air box replacement for a 6.0 PSD. Anyone know different? Thanks, Pat

[JoeH]

Originally Posted by PatO

A quick look around didn't find me any aftermarket CARB compliant DIY air box replacement for a 6.0 PSD. Anyone know different? Thanks, Pat

Most of the 6.0 diesel heads that modify the stock air intake are changing injectors, ignition timing, etc and going for 500rwHP.

[PatO]

Originally Posted by JoeH

Most of the 6.0 diesel heads that modify the stock air intake are changing injectors, ignition timing, etc and going for 500rwHP.

OK, I was looking at it more as anything to incrementally improve any of the original design performance restrictions is a good thing for the long term. My first 100 miles on the FICM 40HP PHP program is like WOW, this brick is waking up! It has potential.

[JoeH]

Originally Posted by PatO

OK, I was looking at it more as anything to incrementally improve any of the original design performance restrictions is a good thing for the long term. My first 100 miles on the FICM 40HP PHP program is like WOW, this brick is waking up! It has potential.

Agreed. I have a 65rwHP tune on mine but was concerned about a slight advance in timing increasing heat. Killing the kitty and a high flow muffler lowered my EGTs 150 to 200 degrees under most conditions. Anything to increase flow is good but apparently the stock intake design is pretty good. At least for the F series. Not sure how different the vans are.