DIY shorty cai

[fastfreddygassit]

I wanted to optimize the top end feel of my car since I have extractors, 2.5\" exhaust, hi-flow cat and aftermarket cams fitted.
So I turfed my mania CAI (Ben has it now ) and made my own dodgy shorty CAI.
Obviously, I haven't made a heat shield yet but that can wait for another few weeks..


All up cost was around $100 with the silicone joiners, hose clamps and 3\" mandrel bends.
The 90 deg bend into the throttle body I had to heavily modify with relief inserts so that it cleared
the top radiator hose. But I had the mig out to weld the tubes for the cam cover hose and the idle hose (?) so it wasn't too big a deal.
The AFM I have obviously moved closer to the throttle body and to do this I just soldered 40cm or so of extra connector wires.
To drive, there is a very noticeable improvement in throttle response and there is a decent top end rush from about 4.5-5k onwards.
It feels \"flat\" at about 4k but that is to be expected due to the removal of the #2 resonance chamber and the inherent timing retard that the 1.8 has at that area.
I will probably make another one if I can work out an acceptable way to reroute the top radiator hose.
A couple of the boys came around yesterday for an impromptu dodgy afternoon (no food-only coffee) so it was decided to paint the intake and the rocker cover with crinkle black.
Didn't turn out too bad as it was done when dark, and I used my plastic welding/heat gun to \"cure\" the paint.
Dodgy indeed!

While we were at it, I wanted to see if Bens seats would fit in my car as I have a style bar and a hardtop.
The seat cleared the style bar nicely and to do up the rear hardtop latches, one only has to recline the seat forwards.
No sweat, no problems
Now to buy seats.
I have to admit, the red looked very, very nice.

[irwin83r]

any pics of intake and cam cover? if you un-ravel the wires on the intake you dont need to extend them...
what filtter you using?

[fastfreddygassit]

any pics of intake and cam cover?

umm...there is an image in the first post with the intake and cam cover painted black. Isn't the image showing up?

if you un-ravel the wires on the intake you dont need to extend them... what filtter you using?

I had to extend the AFM cable (5 wires) and no amount of unraveling would make them longer
I am pretty sure that the JR CAI kit comes with an extension for the AFM wires to put the AFM in the current position
Maybe the NB is different.
The filter is a generic pod filter that I used to run on my 180SX and I just had lying around.
I contemplating getting a slender 3" K&N and actually fabricating a JR CAI replica system.
It depends how I go with the top radiator hose.
I have no idea how the mania enlarged intakes clears that hose and I don't really like the idea of the intake rubbing hard against the hose.
Hence the relief cut-out (not visible in image unfortunately).
Any suggestions?

[Fatty]

nice work, looking good mate. glad to see that strut brace finally found a home too!

[fastfreddygassit]

nice work, looking good mate. glad to see that strut brace finally found a home too!

hehe...Ta for the strut brace.
But with it I faced a dilemma..
I wanted the relocated AFM and enlarged intake.
But it would only work with Mania CAI and no strutbrace or visa versa.
In the end, the Mania CAI got the flick cos I really like the look of the strut brace, no matter how inefffective it may be.
As an aside, the Mania CAI was a NB version that we got to fit on Bens 1.6 with minimal hassle.
Cannot wait for your official dodgy day replete with wingzzzzzzzzzzzz
(there are going to be wingzzzzzz???)

[Fatty]

if you can organise me a deep fryer, then yes there will be wingzzz

[stevesports]

are there any benefits from having the AFM closer to the throttle body?

[fastfreddygassit]

if you can organise me a deep fryer, then yes there will be wingzzz

I have one but it is not large (single man, small appetite )
Plus I get my fill or deep fried southern hospitality from my local first name basis KFC
I'll see what else I can organise....

[fastfreddygassit]

are there any benefits from having the AFM closer to the throttle body?

To drive, there is a very noticeable improvement in throttle response and there is a decent top end rush from about 4.5-5k onwards.
It feels "flat" at about 4k but that is to be expected due to the removal of the #2 resonance chamber and the inherent timing retard that the 1.8 has at that area.

I am pretty sure the improved throttle response is due to the decreased "latency" between the throttle butterfly and the AFM. The combination of the enlarged intake
and the AFM relocation has made a difference on the ass dyno...
I have not dríven another NA with an enlarged intake and the AFM in the stock position so I cannot categorically state how much is due to the AFM relocation

[stevesports]

ah ok cheers. i thought that if a relocation of the AFM closer to the throttle body would improve performance, mazda would have done it. Either way lovely work.

[meanmx]

I've noticed that you have stratigically left the crooked stripe out of the picture Freddy . Looks good but then you already know my opinion

Ben

[green_comet]

Should take mine for a drive too see if there is much difference..

[marcusus]

Although I can't see the image for some reason (imageshack sucks like that sometimes), I think it's probably fairly similar to the setup I'm researching.

A lot of people seem to think a very short CAI will give better throttle response, but will reduce power and torque low down. High end is no problems, but low down is where it seems to lose out. Have you noticed this, or has the increased throttle response negated any power/torque losses?

[fastfreddygassit]

Although I can't see the image for some reason (imageshack sucks like that sometimes), I think it's probably fairly similar to the setup I'm researching.

A lot of people seem to think a very short CAI will give better throttle response, but will reduce power and torque low down. High end is no problems, but low down is where it seems to lose out. Have you noticed this, or has the increased throttle response negated any power/torque losses?

Depends by what you defines as down low
I regard changing gears at 5k as short shifting
seriously though, apart from the flatness/dullness/dip at 4k (definately NOT a stumble) I am rapt with the outcome.
BUT, I haven't dríven a NA8 with a mania cai and a mania enlarged intake with the afm in stock positions.
So how much is attributable to the relocated afm or the enlarged intake I cannot say.
To answer your question, I do not feel any loss in pulling ability down low and the top end surge is worth it.
Also to further clarify... the 4k dullness is not a big deal as it serves to further emphasise the top end rush.
Hope that helps.

[irwin83r]

any pics of intake and cam cover?

umm...there is an image in the first post with the intake and cam cover painted black. Isn't the image showing up?

if you un-ravel the wires on the intake you dont need to extend them... what filtter you using?

I had to extend the AFM cable (5 wires) and no amount of unraveling would make them longer
I am pretty sure that the JR CAI kit comes with an extension for the AFM wires to put the AFM in the current position
Maybe the NB is different.
The filter is a generic pod filter that I used to run on my 180SX and I just had lying around.
I contemplating getting a slender 3" K&N and actually fabricating a JR CAI replica system.
It depends how I go with the top radiator hose.
I have no idea how the mania enlarged intakes clears that hose and I don't really like the idea of the intake rubbing hard against the hose.
Hence the relief cut-out (not visible in image unfortunately).
Any suggestions?

odd... i must of scrolled past it before the pic loaded or something...

if you want to make a cold side intake id look into making an air box in the air damn and using a similar piping route from the throttle body as intercooler pipe.. but ive never tinkered with an NA so just somethin to think about...