FJ80 cabin air intake

[subzali]

I would think feshfesh would be in the silt area somewhere.

 

[ssyork]

Just came back from dropping the 80 to the electrician to rectify a few things and went shopping for filter parts.

Will use this to make the outside cylinder shape.
View attachment 1062207

Will cut this to make to top part of the "hat"
View attachment 1062208

Will use this to make the structure
View attachment 1062209

And went and got this mesh box made to house the paper element from a toyota ac filter. Between the mesh so that it does not fall down into the blowers fan.

Will lay everything out before I start.

Looking forward to seeing how this turns out. I contacted the filter wears guy on eBay last year to make a wrap for a filter that I couldn't find. He gladly did it, only charged me around $20-$22. So if you get a filter made and want one I'm sure he can make. Any chance you could measure the intake size? I need it to be pretty close measurements for him. Also some idea of the taper? I might have him make one just to cover the intake. Maybe have him make it a little taller so a piece of the k&n foam placed on top of wire mesh on top of the intake would still fit.

 

[ssyork]

Or make a basket out of wire mesh so the foam could drop in some and be cut to a closer size so the edges would be filled in better. Either choice the same wrap should work I would think

 

[surfpig]

Thats a great idea. The only problem is when it gets clogged not much air will pass through the vents on the cowl.

I have those pre cleaners filters on my 1/5 Five T Losi filter. They work well with a sponge filter.

Talking grain size. I consider feshfesh dust and not sand. Would that be fine sand on the charts below ?

View attachment 1062199

http://en.m.wikipedia.org/wiki/Grain_size

I would call it very fine silt...

Nice work so far.

 

[Arabian Cruiser]

Ok guys. Did like 5 years worth of R & D in about an hour today.

Ended up far from where I thought I'd be due to the space constraints and material at hand. But I like where I am, except I turned on the blower after full installation and I'm going to need to reduce the thickness.

Here is what I did.

So first step was to dismantle the BBQ grill type thingy and replaced the metal mesh in side with this paper element from toyota and the chicken wire mesh I got.

Then I duck taped it to stop any metal on metal contact and noise.

Stuffed it over the scoop and placed a sheet of green foam to keep it in place.

Didn't work. There were gaps not large but they defeat the point. The problem is that it being so rigid anything bigger will not fit into the hole I cut.

So placed a curtain of red sponge around it to close any gaps and keep it in the center over the scoop. The idea here was to create a loop of red sponge but it would be physically impossible to install and remove without damaging the sponge hoodie.

The problem with that is its touching the wiper motor and arm and its touching the cowl floor which would mean it would pick up any water going through and soaking.

Next idea.

So having studied the scoop more closely I noticed that it seems the designer who designed it must have died at his desk before he could tell anyone what he did.


The scoop itself has its furthest side wall higher than the closest side wall to the access hole. Also the nearer side had flat tabs for what looks like a place for a filter to slide in stop against the further wall and clip into the nearer side. This would need me to go to the junk yard rip a scoop out of the cowl and bring it home to sit and make a glove fit. I'm going up to the junkyard on Saturday to collect all the bolts and nuts from all the 40 s and 80 I can see so will have a look and see if there are any 80 I can take the scoop from.

So the next idea works best for now but as mentioned i need to reduce to the foam thickness. It needs development.

Prototype 1

Placed a red foam sheet with a small bit of mesh to keep it firm and steady.

Tied it in with a couple of zip ties to keep it in place.

I cut some paper element and placed it on top of the foam and mesh.

Then placed another sheet of the red foam on top of that.

Then I wrapped the edge with sticky back foam tape. To give it a better seal in the edges and to keep it together.

That's with it stuffed into the scoop.

Then I worked on a cover for the hole I cut into the cowl cover.

Got a sheet of waterproof sponge and placed it on some mesh for support and put a lip around it to hold it in place when closing the cowl cover over it.

And my baby is alive.

Will work on improving the overall structure of filter and size. Will also add a wire hook on either end to keep it from falling in by any chance and for pulling it back up.

As it is now, it would need new sticky back sponge tape and a paper element on every service.

Will see how I can make it better than that.

 

[Arabian Cruiser]

Just got an amazing idea on how to trace the exact shape and size of the scoop. Will go out with soldering wire and mold it to the scoop and have a perfect fit made up. Also have come up with a great way to create a cavity within the sponge to be able to place the accordion type paper element within the foam structure to keep it wavy and not flat like how I've don't it. There must be a reason for that design.

Stay tuned.

 

[Backwoods Rambler]

The paper element is wavy (accordian shaped) to increase it's surface area (filter area) within a more confined space.

 

[Dubbinchris]

http://www.ecstuning.com/Search/SiteSearch/Cabin_Filter/5#Climate_Control:Filters:Cabin_Filter

Tons of cabin filters here. They also sell housings. The one on my Audi is a pretty simple housing and filter.

 

[Pin_Head]

I wish you success, inshallah.

I am still cleaning the feshfesh out of my ears from my day at Bahra.

 

[Arabian Cruiser]

http://www.ecstuning.com/Search/SiteSearch/Cabin_Filter/5#Climate_Control:Filters:Cabin_Filter

Tons of cabin filters here. They also sell housings. The one on my Audi is a pretty simple housing and filter.

Wow. That's a score. They seem to have everything. Thanks.

Once I have the correct size I'll share.

 

[Arabian Cruiser]

I wish you success, inshallah.

I am still cleaning the feshfesh out of my ears from my day at Bahra.

: ) thanks.

 

[ssyork]

Any chance you could measure the intake hole for me?

 

[Arabian Cruiser]

Any chance you could measure the intake hole for me?

Sure will get you exact measurement once I go back in there tomorrow.

 

[ssyork]

Sure will get you exact measurement once I go back in there tomorrow.

Thanks!

 

[izzyandsue]

Just a thought, but that first trial, what if instead of using sponges to mechanically secure it, you used a large rubber band? Looks like is possible as some of the front/back surfaces of the hole are flat. Just wondering if a crossed band over the filter and then into the flats (or make the flats with more acute angle) could hold it place and keep it away from wiper arm and dry.
The benefit could be using a standard pleated filter or carbon infused pleated, and reusable rubber band, meaning an elastic material that could last a while and not break up in extreme cold or heat like latex or buna N.

Thank you so much for taking leadership on this problem, you have blazed an awesome trail here for us.

 

[Arabian Cruiser]

Managed to go to the junk yard today to get another cowl cover to start working on the modification and some plastic drain grills.

I have since been busy trying to get the perfect size to be able to continue to develop prototype 2 and to share with you the sizes.

I'm getting there. The main problem is I couldn't find my thick soldering wire and the thin stuff is too floppy to work it around the inside of the funnel with one hand. So I wrapped it around the outside and between the strange shape and a few bends in the funnel is came out big. So I'm trying to reduce the cardboard template in size to get the perfect fit.

You might have to wait one more day for perfect size.

If I can find the thicker wire will get it done in one sec.

 

[Arabian Cruiser]

Just a thought, but that first trial, what if instead of using sponges to mechanically secure it, you used a large rubber band? Looks like is possible as some of the front/back surfaces of the hole are flat. Just wondering if a crossed band over the filter and then into the flats (or make the flats with more acute angle) could hold it place and keep it away from wiper arm and dry.
The benefit could be using a standard pleated filter or carbon infused pleated, and reusable rubber band, meaning an elastic material that could last a while and not break up in extreme cold or heat like latex or buna N.

Thank you so much for taking leadership on this problem, you have blazed an awesome trail here for us.

Yes it could be done. The new template I'm working on should be a very snug fit and possible to incorporate clips to attach to the funnel gutters.

 

[Arabian Cruiser]

I think I now know what it feels like to be a vet having to do things by feel only. Nightmare.

Ok I managed to get the best possible shape. Had to braid the thicker wire to give it more stiffness.

I don't know what's the best way to measure it as it's not a square

Any ideas on the best way to measure it ?

 

[Arabian Cruiser]

Have started to develop the second prototype. If it works I'll make a hard shell that will clip in on top of the funnel / scoop and hold a modified paper element. Will be very easy to replace the element only.

It's very basic now just for fit. I plan on increasing the space of the paper element to draw more air.

 

[Arabian Cruiser]

The paper cartridge will look something like this.

It will slot into a filter case which will be permanently in position. It will have to draw air from the front of vehicle position to avoid sucking in any water.

Bed time.