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-   -   Today's Project - PVC CAI (http://www.jeepgarage.org/f6/todays-project-pvc-cai-5945.html)

GCL06 01-27-2010 05:13 PM

Today's Project - PVC CAI
 
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.

http://i787.photobucket.com/albums/y...6/DSC00582.jpg
http://i787.photobucket.com/albums/y...6/DSC00586.jpg

I had read a post about making a PVC intake (http://www.*********.com/forum/f67/h...siable-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.

http://i787.photobucket.com/albums/y...6/DSC00585.jpg

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

Scottina06 01-27-2010 05:33 PM

Re: Today's Project - PVC CAI
 
theres several PVC intake how to's on here bro...but we welcome yours for the 3.7 V6.

Matt 01-27-2010 06:55 PM

Re: Today's Project - PVC CAI
 
I have a link in my sig - that thread also links to another one (in the OP).

How are you planning on mounting to the TB?

Feel free to ask any questions!

GCL06 01-27-2010 07:25 PM

Re: Today's Project - PVC CAI
 
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

GCL06 01-27-2010 09:07 PM

Re: Today's Project - PVC CAI
 
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.

Matt 01-27-2010 09:10 PM

Re: Today's Project - PVC CAI
 
Cool. Pics?

It seems I get better gas mileage than most of the 3.7l guys, LOL.

mon_21 01-27-2010 09:15 PM

Re: Today's Project - PVC CAI
 
oooohh I remember those pvc pipes....lol

LTrainGC 01-27-2010 09:18 PM

Re: Today's Project - PVC CAI
 
Jesus 14.2 around town with the 3.7? I get that with the Hemi.

Matt 01-27-2010 09:19 PM

Re: Today's Project - PVC CAI
 
Quote:

Originally Posted by LTrainGC (Post 139663)
Jesus 14.2 around town with the 3.7? I get that with the Hemi.

I'm at 15.8, LOL. And I do enjoy some spirited driving here and there :D

GCL06 01-27-2010 09:36 PM

Re: Today's Project - PVC CAI
 
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.
http://i787.photobucket.com/albums/y...e/DSC00587.jpg

Then removed the air intake sensor (correct term?). Twist and pull out.
http://i787.photobucket.com/albums/y...e/DSC00589.jpg

Then loosened the clamp on the throttle body behind the air box.
http://i787.photobucket.com/albums/y...e/DSC00590.jpg

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:
http://i787.photobucket.com/albums/y...e/DSC00591.jpg
Right:
http://i787.photobucket.com/albums/y...e/DSC00593.jpg
Left:
http://i787.photobucket.com/albums/y...e/DSC00594.jpg

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.
http://i787.photobucket.com/albums/y...e/DSC00595.jpg

Remove the top of the stock filter box. Pull off the hose.
http://i787.photobucket.com/albums/y...e/DSC00596.jpg

Tested the unfinished piping and filter to get an idea of placement and sound.
http://i787.photobucket.com/albums/y...e/DSC00598.jpg

Had to cut 5 inches off the end of the 2' tube.
http://i787.photobucket.com/albums/y...e/DSC00599.jpg

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.
http://i787.photobucket.com/albums/y...e/DSC00600.jpg

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.
http://i787.photobucket.com/albums/y...e/DSC00601.jpg

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.
http://i787.photobucket.com/albums/y...e/DSC00602.jpg

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.
http://i787.photobucket.com/albums/y...e/DSC00603.jpg

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.
http://i787.photobucket.com/albums/y...e/DSC00604.jpg

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).
http://i787.photobucket.com/albums/y...e/DSC00605.jpg

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.
http://i787.photobucket.com/albums/y...e/DSC00606.jpg

I plan to remove the pipe to spray paint it as soon as I get the chance.

GCL06 01-27-2010 09:38 PM

Re: Today's Project - PVC CAI
 
Quote:

Originally Posted by LTrainGC (Post 139663)
Jesus 14.2 around town with the 3.7? I get that with the Hemi.

Sad isn't it! The 31s don't help. Nor does the lead foot. Nor does traffic and traffic lights and long ass lines in the school parking lot.

GCL06 01-27-2010 09:38 PM

Re: Today's Project - PVC CAI
 
I'll record a video of the intake tomorrow and post a link here.


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