i mean u might have to make an adapter i know its abit small from what i can remember but that will only speed up the air flow then u can open it back up. it would also allow for colder air to be pushed inward... get it just right with a CAI might get even more horses

 

So I was in the basement the other day, and I remembered that I still have to finish this project! It has definetly been a while, but I gave up last time because I couldnt get the headlight out. Tonight, I got the headlight off and had access to the inside of the fender and got the ram air fabrication complete. Tomorrow I will remove it from the truck, spray it black, seal all the joints and put it back on the truck. And of course, before I closed up the garage I remembered you guys and took some pictures and a video. Enjoy!

Ill post air intake temps tomorrow when the sun is out to see if there is any difference. Any questions or comments, feel free to post!

http://www.youtube.com/watch?v=dGkpaX8tORo

Engine Compartment:
2010-07-10231212.jpg

Behind the headlight (with a lot of mud):
2010-07-10231201.jpg

The scoop with aluminum screen installed:
2010-07-10231044.jpg

Close up of the scoop:
2010-07-10231052.jpg

The bolt/wingnut to mount the scoop to the bumper:
2010-07-10231108.jpg

Ground shot:
2010-07-10231123.jpg

Pipe below coolant tank:
2010-07-10231131.jpg

Bolt/wingnut mounting the intake to the wheel well:
2010-07-10231140.jpg

Shot from below:
2010-07-10231149.jpg

 

Nice fabrication work. I hope you get good results from it. It should certainly provide cooler air to your intake and that is always a good thing.

 

Thanks Blown. It gets kind of sloppy in some spots, but no one will ever see it anyways. And when I go to sell the truck, Ill just rip it off. Im anxious to see what my new intake temps will be!

 

So it was 85 degrees today, and not really any sun. I got in the truck and the IAT was reading 91 degrees before starting the engine. I warmed it up and parked it at a local store, came back in 15 minutes and the temp was reading 130 degrees. Moving constantly at 50mph, the temp comes down to 103 degrees, which isnt too bad. The problem is with stopping constantly in the city, by the time you get cool air moving you have to stop again. On the highway Im sure there will be excellent results.

 

honestly man that is tight! lol you shoud seriously market this thing and sell it! I want to buy one from you...seriously man you think you would like get these things done for interested buyers and send the parts and stuff like you have to us? i would love to have that when i get home from korea and install it on my truck!

 

Good job man

 

Thanks wteboy! I would love to make these things, however its really hard to just market something that I couldnt ship out in one piece. In order to install this, expecially up in the fender, all the pieces had to be individually manuvered, drilled and screwed. Most of it is so close that when Im afraid to take it apart again to paint it in fear that I wont get it back together the same way. Ill probably just remove the scoop and paint that. I can tell you though what parts I used. Here they are:

3" Galvanized Heating Duct found at your hardware store
- 4 bendable pieces of duct (Allows for many different angles)
- 2 36" straight sections (You will scrap most of the second one)
- 1 3" to 6" adapter
- 1 5-6" hose clamp
- JB Weld
- 6 small machine bolts with wing nuts
- About 30 small sheet metal screws
- Less than 1 sq ft of aluminum screen
- 1 3" PVC pipe, about 1 inch long
- Galvanized metal primer
- Spray paint

You will need to remove the headlight which requires a torx driver and one hell of a pull on the light straight out after the bolts are removed. You will need a couple drill bits, a drill that can fit in to tight spots, a tin snips, a pliers to bend sharp edges, and a torch to make bending the scoop easier, plus some misc tools depending on your application that may help you out.

The scoop was the first thing I did. I used a torch and heated two sides of it until both were glowing red. You will need a metal sledge hammer, bar, or something big enough to flatten the scoop out by pressing it down on the ground. I flattened mine perfectly the first time, and it fit nice and snug in to the bumper. The piping that connects to the adapter will fall off because the bending of the scoop will distort the perfect circular opening. For this, I used JB Weld to reattach the piping so I could connect the duct to run up to the air box. (Be careful heating galvanized pipe. The zinc fumes are toxic and cause MAJOR problems in your lungs if you inhale them)

The screen I installed was between the scoop and the first piece of duct.
I trimmed a 4" diameter circle of screen, knotched some of the edges down to a 3" diameter circle, placed it flat on the piece of duct and pushed the scoop down on the the pipe and screwed it in place.

Next I just test fitted all the pipe. For the pipe entering the fender; the galvanized duct has 2 sides. A "male" and "female" side so they will fit in to eachother. The male side will go through the hole in the fender pretty tight, and only about an inch. It is perfect because you only have to secure the side of the pipe that came through the fender to the engine compartment. I did this by putting the piece of 1" long, 3" inner diameter PVC over the galvanized pipe, drilling 4 holes and using 4 of the machine bolts and wing nuts to tighten it on. All the other pipe was installed piece by piece, and held together with 2-3 sheet metal screws at each joint. You have to pre drill the holes and then put in your screw. After I paint it, I will be sealing all these joints so none of the screws can fall out over time causing the intake to fall apart.

The pictures should show enough detail on how I ran the pipe to give you an idea of how to lay everything out.

For the mount to the wheel well; I took a hose clamp and lightly tightened it around the straight section of pipe. Then I took my drill, and through the extra piece coming off the hose clamp and through the wheel well I drilled a hole. I then took one of the bolts and wing nuts and secured the clamp to the wheel well which holds the intake in place perfectly.

After all the pipe is screwed together, and it is mounted to the wheel well is really wont move much. But, at 80 mph the amount of air force coming through the pipe will be alot, so I also bolted the scoop to the bumper. The scoop is already tight so it didnt move much without the bolt. The bolt is a little insurance though. I simply just put a bolt through the bottom of the bumper and scoop, and used a wingnut to tighten it on. The only way that scoop is coming out is if the bolt rips through the pipe or the scoop actually bends .... which isnt going to happen with wind. That galvanized metal is pretty sturdy.

Thats basically everything. If you still would want to buy a "kit" I could get everything in a box for you, with the scoop and screen attached to the first piece of pipe. I wouldnt do this for atleast 6 months though (I think I read that you are in Korea until then so I dont think it would be a problem) but the reasoning is Im not sure how this will hold up. With the winters here in wisconsin, and driving at high speeds on the interstate this thing may be garbage after a couple months. So I would first see how it holds up before I start putting anything together for other members so I dont end up selling garbage. Making one yourself isnt too bad though. The worst part is the cuts you get on your hands from dealing with the sharp metal. Im sure we could work something out though. Otherwise, I am always on the 3rd gen dakota section. Just post a new thread, use this one or send me a PM and I can answer any questions.

 

yeah man let me know whats up...

 

Where did you get the 3-6" adapter? I have built something similar, but I used 3" flex dryer duct. I was at Home depot and Lowes, and did not see one. Mine seems to help, but I like your idea of a scoop at the end.