Well I have been working on my custom lower intake this week finally, I decided to make the prototype out of wood since its cheap and easy to work with and strong enough that I can actually bolt it on the mock up motor to test fit. I was originally using acrylic but its too damn expensive and fragile.

Anyways, Here are the pics and explanations that go with them.

Front shot, shows the extra idler pulley I will need near the AC compressor(delete pulley), this is to ensure good belt wrap.



A different angle, you can see how far forward the blower sits, the intake actually hangs over the timing chain cover quite a bit, I had to use a 99+ cam sensor otherwise the custom intake will hit the older larger style Cam sensors. No biggy though.



Here is a pic of the intake on the motor without the blower. I still have to dig out the tub about another 1.5 inches, I can probably get away without the tub inthe oil valley but I want the extra volume and plus if I decide to add an IC in the future it will give me the needed room. Also notice the front part of the tub is curved where its cut out, I may square this off eventually, the saw I was using wouldn't allow my to square it off but the blower actually angles the air backwards so this curved part may be more beneficial then if squared off, the IC ont he Cobra blower sits towrads the back of the blower, so underneath its actually angled that way.

The opening in the rear of the intake will eventually be closed up, but if I install an intercooler it will have the inlet and outlet pipes through that opening.

You can also see why I am having an issue with where to put the coolant passage, not much room up front but lots of room out back, If I move the coolant passage out back I think I can get the coolant to enter the rear of the intake instead of the front and just put an inline thermostat housing int he upper rad hose.



Here is the intake off the motor you can get a full view of the tub with this shot. My openings for the ports are badly done, I didn't have the right bit for my dremal and a drill just didin't work too good. Notice the layer of plywood ont he top of the intake that was to get the proper height I wanted, but I may add one more layer of plywood to raise it even more, you'll see why in the next set of pics.



Here is a shot with the blower on the intake.

 

Rear shot of the blower on the intake.



Here you can see inside the intake with the blower installed, the part the IC originally bolts to sits below the top deck of the intake, this is why I might add another layer of plywood to make it sit flush.



Here is a shot with an extra layer of plywood, see how it sits more flush now, and doesn't block the ports to the heads at all this way, but it does cause more of a problem with the injectors now.



With the single layer of plywood I can get the fuel injectors to clear pretty good, I can actually take that first layer of plywood off and have no plywood and with the blower sitting that low I get lots of clearence for the injectors but it sits too deep in the intake and blocks half the ports tot he heads so it had to be raised by at least one layer of plywood.

Here is the passenger side front injector that is a problem, see it wants to hit that casting mark ont he mounting tab, I think I can get away with just removing the casting mark and maybe take a little off the actual mounting tab and it shoudl clear fine, I need to use the 99+ pencil style injectors for sure.



Here is a shot of the drivers side, you can see this one directly interferes with the mounting tab, but I think I can cut the mounting tab off and put a hole inthe casting tab and use that as the mounting tab, it sits higher but I just have to put a tab on the intake to obtain the proper height.



I am starting on a new improved prototype today, one that will fit much better

 

I love to see this car in action if this all works

 

Looks awesome, can't wait to see the finished product.

 

Damn man, thats pretty sweet. When you planning to have it all on and running?

 

no idea, I only work on it when I get a chance, just had a bit of time this week thats all, I am in no rush to finish it really, but would like to get it done sooner then later of course.