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Standard Air Box Modded To Frp Putting a tutorial together

#21 User is offline   spyronx 

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Posted 26 May 2008 - 04:03 PM

when will this tutorial be finished?? im very interested.

#22 User is offline   3Ddunk 

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Posted 26 May 2008 - 05:44 PM

Sorry been very busy last few months, will get on to it a soon as i can.
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#23 User is offline   3Ddunk 

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Posted 01 July 2008 - 08:45 PM

Well heres some pic will try and edit it abit better soon, been busy building cars.



One real FRP airbox, you can see the front air feed in the top right of the box.



Battery and holder removed as well as rubber hose



Bottom half of airbox removed, you can see the side air feed.




FRP box on left Standard on right (top half)



Break the plastic weld (all five) and remove the sound baffler




Should just flick out with screw driver



And now the harder bit, cutting the hole in the front
































This post has been edited by 3Ddunk: 01 July 2008 - 08:49 PM

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#24 User is offline   arcdef 

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Posted 01 July 2008 - 10:22 PM

without sounding too stupid, where does the tubing lead to? the lower grill?? if you could show a picture of that it would be great!

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#25 User is offline   swipedizzle 

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Posted 12 July 2008 - 03:24 AM

yh am abit lost 2 :$

#26 User is offline   3Ddunk 

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Posted 12 July 2008 - 07:41 AM

It goes between the lower grill and the radiator.
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#27 User is offline   PussCat 

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Posted 12 July 2008 - 08:05 AM

the tubing doesn't actually 'go' anywhere, it just kinda sits there, as dunk says, in the gap between the lower grill and the radiator...

Don't know how it would work on a standard puma, but mine and Dunk's have been modified to put an elbow on the front, and a hole through the platic plate that sits in the passenger side of the bumper behind the lower grill, to give a direct air feed from the front.

I'll see if I can find a pic....
Caz



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#28 User is offline   e3silversurfer 

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Posted 12 July 2008 - 08:15 AM

do you have to remove the entire battery + battery holder to get the airbox removed???

#29 User is offline   3Ddunk 

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Posted 12 July 2008 - 08:17 AM

It does help
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#30 User is offline   e3silversurfer 

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Posted 12 July 2008 - 08:19 AM

hmmmm ok, thanks for the tip smile.gif would you reccommend using silicone?? or hot glue gun to hold the pipe there?? I only have silicone at home smile.gif

#31 User is offline   PussCat 

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Posted 12 July 2008 - 08:19 AM

pic of the new air intake...



we used the 'end' off the original air feed pipe, trimmed down a bit and glued into position in the hole cut in the blanking plate, and had to use a new (longer) bit of flexible ducting to replace the original....
Caz



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#32 User is offline   e3silversurfer 

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Posted 12 July 2008 - 08:21 AM

that area is occupied by a fog lamp on my puma... might have to look for another site to route the pipe to smile.gif

#33 User is offline   Dan 

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Posted 12 July 2008 - 08:41 AM

A few Qs...

1. Is the flexi-pipe the one on the std airbox which goes down into the wing?

2. What's the diameter of the drainpipe?

3. Is that a standard hot glue gun or is there something fancy about it (I have a loctite one just with standard glue sticks).

#34 User is offline   3Ddunk 

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Posted 12 July 2008 - 10:14 AM

QUOTE (e3silversurfer @ Jul 12 2008, 08:19 AM) <{POST_SNAPBACK}>
hmmmm ok, thanks for the tip smile.gif would you reccommend using silicone?? or hot glue gun to hold the pipe there?? I only have silicone at home smile.gif


I used hot glue, make sure you rough up the surfaces to help it stick
QUOTE (Dan @ Jul 12 2008, 08:41 AM) <{POST_SNAPBACK}>
A few Qs...

1. Is the flexi-pipe the one on the std airbox which goes down into the wing?

2. What's the diameter of the drainpipe?

3. Is that a standard hot glue gun or is there something fancy about it (I have a loctite one just with standard glue sticks).


1.Yes the flexi pipe is the one found in the wing, cut a bit shorter and moved to the front.

2. 68mm Diameter Ford Racing Pipe (or in the real world B&Q wink.gif 2M long drain pipe think it was about £5)

3.The hot glue gun was from Lidl it cost £5 they also had a box of 32 glue sticks for £2 lot cheaper than B&Q. It alway worth a look in Lidl, Aldi and Netto for cheap tools as they are far better quality than the large chain diy superstores.
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#35 User is offline   platty30 

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Posted 12 July 2008 - 11:03 AM

good work, but I cant help thinking the FRP airbox looks abit Heath Robinson. Im not knocking your work, youve made an exact copy, just cant believe that Tickford in all its glory didnt mould a complete new bottom half. It actually looks like some poor sod had the task of cutting out the front section so he could glue back in some down pipe

Never ASSUME. It makes an ASS out of U and ME.

#36 User is offline   R5CPD 

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Posted 12 July 2008 - 12:15 PM

QUOTE (platty30 @ Jul 12 2008, 12:03 PM) <{POST_SNAPBACK}>
good work, but I cant help thinking the FRP airbox looks abit Heath Robinson............


There speaks a man that has not owned a FRP. wink.gif

I've spoken with Dunk before about this, as my Thunder has a similar, but slightly simplier arrangement using bits from a Fiesta Zetec-S. wink.gif Boreham put a lot of work into the FRP airbox and did consider cone filers, etc as other possible options. However. the design you see here was felt to be the best, so you could do alot worse than to follow the above advice. smile.gif

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#37 User is offline   platty30 

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Posted 13 July 2008 - 10:00 AM

Dont get me wrong, im not knocking the advice given. I Think the advice is spot on. I wouldnt even call it a copy of an FRP airbox as looking at the factory airbox, Tickford was also in the queue at a DIY store with a few lengths of downpipe, and a hot glue gun! ph34r.gif

Im not sure who to laugh at most, Ford for spending tens of thousands of pounds creating mouldings for all the poxy pipework you find up inside the wing on a standard airbox. Or Tickford for saying to an engineer, heres £10, make this work properly! biggrin.gif


Never ASSUME. It makes an ASS out of U and ME.

#38 User is offline   halfpastsix 

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Posted 11 August 2008 - 10:17 PM

I'm not sure I'd want to put the air intake that low in the grill. I'd be worried about water going up it when I did my favourite passtime of driving through massive puddles at silly speeds.
I've not had my airbox off yet to have a look. Do the standard Puma boxes only have the air intake at the sides? And what do you do with the small hole that is left at the side when you do this mod? Or will it all become obvious when I take the thing to bits?
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#39 User is offline   3Ddunk 

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Posted 12 August 2008 - 07:28 AM

QUOTE (halfpastsix @ Aug 11 2008, 10:17 PM) <{POST_SNAPBACK}>
I'm not sure I'd want to put the air intake that low in the grill. I'd be worried about water going up it when I did my favourite passtime of driving through massive puddles at silly speeds.
I've not had my airbox off yet to have a look. Do the standard Puma boxes only have the air intake at the sides? And what do you do with the small hole that is left at the side when you do this mod? Or will it all become obvious when I take the thing to bits?


To answer your questions.
All the FRP have the air intake that low in the grill, Ive just added an elbow at the end.
The FRP uses both side and front air intake, just that they removed the flexiable hose from the side to use at the front, the elbow is still there.
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#40 User is offline   Max M4X WW 

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Posted 12 August 2008 - 06:04 PM

The ducting shown above is 'anti water' stuff I think anyway. Try running some water through it, I think it will just come straight out of the holes?

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