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Today's Project - PVC CAI

18K views 93 replies 17 participants last post by  GCL06 
#1 · (Edited by Moderator)
I was feeling very industrious again today. Picked up a shorty antenna from Advance Auto Parts for $6 and (though unrelated to Jeeps) some guitar wall mounts.




I had read a post about making a PVC intake (http://www.*********.com/forum/f67/homade-3-7-intake-possiable-956199/) and thought I'd give it a go. Figured if nothing else it could be a temporary swap until I can afford a K&N if this one's not up to par. I already had some paint and a 90 degree elbow.



3'' x 2' PVC pipe - $4
PVC cement - $6
45 degree elbow - $3
Spectre Intake Filter - $25
Spectre Coupler - $8

Total - $46

I plan to remove the air box and run the pipe straight to the throttle body using the silicone coupler.

Pictures and a how to guide will be included as they come along :D
 
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#4 ·
If a mod could move this to Performance that'd be great. Accidentally put it here >.<

I cut a piece of the stock intake tubing where it connected to the air box and stuck it on the end of the PVC pipe. Put some duct tape around it and used a lighter to melt it air tight. Then just going to tighten the clamp to the TB.

So far its good! Did a quick sound test and like it. Letting the PVC cement dry then back to work. Think I'll have to remove the piping to paint it tomorrow though - need the Jeep to get to school haha
 
#5 ·
Success! Got it clamped on, air sensor in the hole, supported - just need to paint it tomorrow!

Took it for a test drive and this things awesome! Instant difference! No more lag time between pushing on the gas and feeling the Gs, just sucks my ass back in the seat. Sounds great too. Noticeable difference in power.

Going to be resetting my EVIC to see what kind of mileage improvements I'm getting. I've been at 14.2 over the past 1.5k around town, to and from school, very little highway mileage.

Now to work on the how-to.
 
#10 ·
How To Build a PVC Intake for a 3.7L V6 Grand Cherokee

Parts
- About 2' of 3'' diameter PVC pipe
- 1 45˚ elbow for 3'' pipe
- 1 90˚ elbow for 3'' pipe
- High Flow Intake Filter (I used Spectre)
- Duct Tape
- PVC Cement

In total it cost me right around $50 to make!

Tools
- Saw to cut PVC pipe and stock hose coupler
- 5/32 alan wrench (best if on an extended screwdriver)
- Flat head screwdriver to remove the air box
- Scissors to cut tape
- Drill bit to drill the air intake sensor hole
- Lighter to melt the duct tape air tight
- Sharpie


Started by removing the stock intake hose. Just loosen the clamps on both ends.


Then removed the air intake sensor (correct term?). Twist and pull out.


Then loosened the clamp on the throttle body behind the air box.


Used a 5/32 alan wrench to get the right side of the air box off. Very tight spot - recommend using an extended screwdriver bit as I had to buy one anyways to reach the left side.
Right:

Right:

Left:


Once the clamps and both screws are removed the air box may be removed. Just had to shift it around different ways until it squeezed out.


Remove the top of the stock filter box. Pull off the hose.


Tested the unfinished piping and filter to get an idea of placement and sound.


Had to cut 5 inches off the end of the 2' tube.


Cut the end of the stock intake hose to use as a coupler for the elbow to the throttle body. Used duct tape to connect the coupler to the pipe. Used a lighter to melt the tape to an airtight seal.


Test fitted the pipe. Used the 5'' piece cut off earlier to connect the 45˚ elbow to the 90˚ elbow which will connect to the throttle body via the coupler made from the stock hose.


Once I found the correct angle for the pieces to connect I used a sharpie to draw guidance lines. Then used PVC cement to stick all the pieces together.


Drilled a hole for the air intake sensor to fit in. Once finished drilling I used a Swiffer cloth on the end of a pole to clean out the inside of the pipe, then blew it out with a shopvac and vacuumed after that. Don't want any shavings getting into the engine.


By now it is obvious - this thing is ghetto rigged. To top it all off I duct taped a sponge up and zip-tied it in place to support the pipe.


A view of the pipe. 90˚ elbow with the coupler on the end, to the 5'' straight pipe, to the 45˚ elbow, to the remaining straight pipe (had to cut off more to get it to fit right. Ended up protruding from the 45˚ 8 inches).


Installed it. Tightened the clamp to the throttle body and the one on the filter. Plugged the air intake sensor into the drilled hole. Made sure everything was snug and took it for a test run! Runs great! Instant reaction when I push on the gas. Much quicker acceleration. Definitely feel a noticeable difference. Will be keeping an eye on the MPG changes.


I plan to remove the pipe to spray paint it as soon as I get the chance.
 
#12 ·
I'll record a video of the intake tomorrow and post a link here.
 
#14 ·
Thanks!

That's the very next thing on the list now that the intake's no longer on there :thumbsup:

Think I'll go queue up now
 
#16 ·
Not sure. I'll have an idea when I get home tomorrow. Been getting 14.2 over the past 1.5k. I can tell there's more power which should mean better mileage. We'll see :p
 
#19 ·
Def gonna paint it. Looks like crap as it is.

I'm not really sure actually. I have some primer and black spray paint left but I'd rather do something more interesting than plain black. Suggestions?
 
#22 ·
^Something crazy would probably be my choice as well.

I'd also like to cover it with some sort of material to keep as much heat out as possible. Any suggested products?
 
#33 ·
Haha thanks for the comments and advice everyone. I just had to push hard enough and the pipes closed the gaps at all the elbows so it's pretty much smooth throughout.




The PVC is connected to the TB using the end of the stock rubber (I think it's rubber?) hose that connected the air box to the filter. Duct taped it on to the pipe and melted the tape to make it air tight and clamped it to the TB.
 
#27 ·
Having run a PVC intake for a LONG time, I have to say that it really isn't worth it. It looks silly and has less-than-ideal functionality because of the way the pipes slip-fit together. You have these huge ridges in the tubing that prevent the smooth flow of air. You'd have to port it to get it smooth, or epoxy the gaps

For 16 bucks a pipe you could run Spectre piping, then 12/coupler w/ clamps. Trust me, it's not that much more expensive and looks SO much better.
 
#34 ·
Still looking for good tape locally before ordering online.

Need to find some good material to keep the heat from the engine from heating the air in the pipe as much as possible. Considered using pipe insulation from Lowes but I don't want to end up letting hot air in and trapping it.
 
#35 ·
And another thing. I bought the materials to make another intake. If anyone's interested in having me make them one send me a PM.
 
#37 ·
I like the idea. Going to have to see what I can do and google some pics. Might even be able to use the stock air box parts :D

Appreciate it!
 
#38 ·
Update - Drove to and from school and to and from Home Depot a few miles down the road and I'm averaging 18.9 mpgs but that's with lighter traffic than usual since I left school before the bell. Still know it's a definite improvement but it will take a few more days of driving to get more precise numbers. Exhaust is noticeably louder for sure!

I'll go take a video now.
 
#39 ·
Update - Drove to and from school and to and from Home Depot a few miles down the road and I'm averaging 18.9 mpgs but that's with lighter traffic than usual since I left school before the bell. Still know it's a definite improvement but it will take a few more days of driving to get more precise numbers. Exhaust is noticeably louder for sure!

I'll go take a video now.
Yeah, it's going to take a fair amount of miles to get a good idea of your true average.

Hell, I can average 22 MPG when I first reset the button.

You'll probably gain around 1 MPG, I think that's right about what I gained.
 
#42 ·
Just a good pic of the heat shield would be great if its not too much trouble :D
 
#44 ·
Sure, one min.
 
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