Drilled Airbox

[wabbit]

I just completed my air box modifications yesterday. My original plan was to drill 3/8" holes in a close offset grid pattern. I wanted a decent looking mod... even though it hardly shows.
The drilling to be done one one side only- the side facing the fender. I felt this would reduce intake temp and minimize the noise projection, and really, the noise issue is not a big factor because the air box is still a good three feet "upstream" of the throttle body. And any changes in sound will only be evident during hard acceleration. Note: I would not recommend drilling the bottom as it barely clears the mounting plate.
For drilling, I wanted a nice even grid of holes so I located and drilled pilot holes with a 3/16" bit. This was a problem... When I went to chase the pilots with the 3/8" bit, it would quickly grab and break through the material. Dead Link Removed Much smaller pilot holes ( < 1/16") would have worked great.
I ended up doing a cut-out of most of the one side, leaving adequate material around the mount tabs and up near the filter element location. I finished with a coarse aluminum screen caulked on the inside border of the hole.
The project turned out great and the acceleration benefits are "stimulating" to put it one way.
Honestly, I dont think McGuyver could have done it better... Dead Link Removed
i'll try to get a picture posted soon....


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'91 Explorer XLT 4WD

 

[GJarrett]

Wabbit:

I DO recommend drilling at least a couple of holes in the bottom because now that you have all that extra ability to ingest air you also can do it with water during a good storm. Your box needs to be able to drain now.

Just food for thought.

Gerald

[This message has been edited by GJarrett (edited 03-23-2000).]

 

[S.Matsushige]

I agree with Gerald on making some holes on the bottom. By opening up the airbox, there is now that slight chance that moisture may find its way into it. The holes on the bottom will help to drain any moisture that finds its way there. I cut four one and a half inch holes on the bottom of mine for drainage.

 

[wabbit]

Mine had existing holes in the bottom. I think there were two on each end. If yours does not, good idea to make a couple drainage holes. It certainly won't hurt to drill the bottom. It just doesn't really help with flow increase. Drill as much as you want but bear in mind, opening up the front and engine side increases your exposure to "splash-up" water.
I haven't "crunched the numbers", but I'm sure that even with only one side cut out, the open flow area is adequate to not restrict the airflow.

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'91 Explorer XLT 4WD

 

[TymeKeeper]

I drilled all sides except the bottom, where I just enlarged the holes that were there already.. Other than that, it looks like swiss cheese..(sounds familiar)... I enjoy the extra power, and my Oil pressure went up slightly, just over half now. I am thinking about cutting out most of it, and putting some screen in there.. but for now this works just fine.

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Jim
'92 Eddie Bauer Explorer
Dual 2.25 exhaust, no Mufflers
Drilled AirBox
Cobra 148GTL W/K40 Mag
235/60's
My Baby!!

 

[wabbit]

Here is a picture of my airbox modification.

www.bewellnet.com/wbacus

It will initially open up to a picture of my Explorer. If you hit "forward" it will show the airbox mod.
This is my first post to the web. I plan on learning more about this site development stuff and hope to develop a Home page with more pics, etc.


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'91 Explorer XLT 4WD

 

[Ira]

Wabbit,
I tried to open the page you are referring to and could not do it. I have tried it with Netscape and IE but neither one of them will work. I would like to see the pics, so if you find the source of the problem, please let me know.

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Ira
91 XLT 4x4

Once I thought I was wrong, but I was mistaken.

 

[wabbit]

Ira,
I tried it and it seemed to work. Did you get an "not found" or???
Anyway, I won't turn this in to computer tech support. Dead Link Removed
I've sent it to you E-mail just in case...

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'91 Explorer XLT 4WD

 

[mikefox]

Wabbit, I went to your link and seen your work. Air box looks good. I also noticed you have a Sony 10 disc CD changer stuffed into the center console. I also have a Sony 10 disc changer but mine is in the back cargo area in my '95. I couldn't figure out how to get the front of my console unscrewed. I would like the changer in the console. I know the '95 cosole is different than the 94 and earlier models. Does anyonelse have any insight for this.

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mike fox
95 XLT 4D 4X4

 

[GJarrett]

Egads, Wabbit, what a great job! That looks way too professional. I'm gonna have to go take a pic of my shredded airbox and post it as a contrasting entry. Dead Link Removed

 

[Trckmagik]

GJarrett You can post it with a picture of your cut off exhaust to! Dead Link Removed

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Brian Green
-2001 Sport Trac
-1992 Explorer 2wd w/ six
inch suspension lift
-1992 Ranger 2wd w/ 5.5
inch suspension lift
Trckmagik@aol.com