The "Official" 1HZ/1HD-T/1HD-FT Airbox/Intake Mod Thread (4 Viewers)

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Donaldson makes washable filters similar to AFE's. One of the Volant boxes might be an option? Cheaper than the stuff from OZ....
 
Put this on yesterday. I suspect my old Safari is preventing it from seeing a difference

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Put this on yesterday. I suspect my old Safari is preventing it from seeing a difference


I was going to ask in your build thread but thought it more appropriate here. What was required to fit the FZJ lid... lengthening the stud? The 3.5" silicone outlet, does it reduce down to match the turbo inlet?
 
I cut down an extension nut and cut down a bolt to extend it. That way I can remove it to stock.

Cut the flange off the lid, 3.5" silicone to 3" 90 degree. I had 3" stainless tubing from my exhaust I just used to go down to the turbo to match my existing fittings.
 
I cut down an extension nut and cut down a bolt to extend it. That way I can remove it to stock.

Cut the flange off the lid, 3.5" silicone to 3" 90 degree. I had 3" stainless tubing from my exhaust I just used to go down to the turbo to match my existing fittings.


Okay, thanks. Do you remember the thread pitch on the extension nut?
 
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Hi guys.
Having been dissatisfied with the available options for a high flow air box I decided to make my own.
The first and most important thing for me was to find a filter with satisfactory air flow capabilities, great dust holding capacity and compact enough to fit in the mighty 80 series.
After much deliberation I decided on the donaldson powercore filter.
Anyone who has been down this road would know that it is near impossible to get any stats regarding flow rates of filters from manufacturers unless it's in their airbox.
I took the chance with this filter which is a direct replacement for the 2006-2008 6.6 duramax. It is also compatible with the isuzu 7.9ltr turbo engine so I figured it would be ample.
Filter p.n. p610875
I then constructed the box itself using two 25mm thick discs of solid aluminum for the end plates, much machining was required to enable a good tight fitment of the seal.
I had a cylinder made up and welded to the back disc (inlet side), machined an oring groove and lip for the front disc (turbo side) to seal on the inner wall of the cylinder.
Cones were attached either end with provisions for pcv inlet and restriction indicator ports. The inlet comes directly from a safari imitation snorkel (3.5")
And outlet (3") via silicone bends to badboy.
I am thrilled with the results, I gained 2psi boost (28lb-30lb) and it pulls much better in the high rpms.
I am yet to test restriction through the box itself but I have discovered a big problem. I have over 50" water restriction pre filter!!!!!!
I thought these snorkels were ample.
3.5" inlet and outlet. What now? Will a 4" snorkel be sufficient or do I need to go bigger?
Cheers in advance.
More photos to come...
 
that's serious machining right there.. looking forward for more pics .. did you have a vacuum meter after the air box / filter ..?
 
that's serious machining right there.. looking forward for more pics .. did you have a vacuum meter after the air box / filter ..?
I tested before and after the filter using a manometer the results were both in excess of 50" water at 3000rpm @ 30lb boost
 
I tested before and after the filter using a manometer the results were both in excess of 50" water at 3000rpm @ 30lb boost
Next step will be testing filter box inlet/outlet to get restriction across filter but that doesn't help my pre box restriction...
 
that looks awesome .. but that aluminum chunk must be almost unobtainable ..

side question .. it's your catch can baffled / filtered inside ..?
 

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