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This is an adaption of a modification that Dean posted last year. The main idea was his, i just seem to have found a slightly easier way to do it. I chose to try this as opposed to cutting a hole in my airbox for a couple of reasons, one of which was fabrication issues another being impact resistance. If you decided to, you should be able to remove the funnel and re-insert the original snorkle with only minor residual effects of having tried this mod. I also recommend at least a K&N filter to compliment this mod. Note- this may make your turbo whine (spool up sound) a bit more promient, more so with other mods.
ok so here's what you need:
-1 black 'Super Funnel' it's an 18" long, slender funnel, i've seen it at a couple auto parts stores (pep boys, autozone) and at wal-mart. The company name on my UPC sticker at autozone is Blitz, but there may be other companies. $1.99 The funnel is almost 5" at wide end and tapers to 1/2". At first it didn't look right, but it worked great.
-1 half-round file (i got an 8" bastard cut file at the hardware store for $12- good thing to have around) a full round file would also be ok.
-sand paper- i got a 3M assortment pack (wal-mart or elsewhere) 100, 150 and 220 grit. or just about anything you have around in this balpark.
-a utility knife or other sharp knife
-a deep pot and a means to boil water (i did this mod in my kitchen and dinette area)
-1 empty wine bottle (do the honerable thing- drink the wine if you don't have an empty bottle) a smoother style neck (like a reisling) works best
-a 10mm socket for you socket wrench (or i suppose a 10mm wrench or something else would suffice)
-perhaps a glove or something to hold the funnel over the boiling water...
these direction are for TURBO NG900's
step one- remove the airbox
4 spring clasps on top to take the upper portion off, then 3 10mm nuts hold the box to the frame. look around you'll find them. don't drop the air filter. Be careful- in my car a little wire was held next to the airbox on a fastener of sorts. Just remove the wire it this applies to your MY. This would also be a good time to get/install a K&N filter to compliment your soon-to-be-modified air box
step 2- remove the snorkle
heat the air box and snorkle under hot tap water (to soften) then use somehting (i used my socket wrench extension) to press in on the little circular tabs while you wiggle the snorkle out. There is a tab on the bottom too, i just worked the top one. This took a good amount of force. start the water boiling at this point about 5-6" of water should do.
step 3- cut the funnel
i cut mine at about 6 1/2" from the wide end. Actually what i did was insert the funnel into the airbox and score the funnel through the hole where the old fastening tab was. Cut here with a utiltiy knife or your implement of choice. I also cut off the little hang tab on the large end of the funnel.
step 4- the filing/snading.
file and then sand (i used 100 and then 220 grit paper) both the large end of the funnel and the internal diameter of the outer part of the airbox extension (where the snorkle was) where the funnel will attach. you want to remove rough, square egdes from the inside of these surfaces for smoother airflow. The goal is a smooth taper at the open end of the funnel and the open end of the air box where the funnel will attach. I even touched up the airbox extension after i had atached the funnel, for a nice, smooth transition.
step 5- moulding and attaching the funnel
I put the wine bottle on the floor near the stove. have the snorkleless air box handy. Hold the funnel in the boiling water (4-5") for abuout 20 seconds- I recommend a glove/mit here. then take the funnel out of the water and press it firmly over the wine bottle with both hands- be sure to keep it straight here. How far you will need to press down depends on your bottle. I had to go to about 1" above the label. You can repete this step as needed. ...
now here's the trick- hold it down on the bottle for like 5-10 seconds, then take the funnel off while it's hot and try to get it over the air box extension. (careful the funnel will be hot) the funnel will shrink while it cools, so you need to act fast and be careful to get the whole funnel over the airbox extension before pressing hard, so as not to buckle the funnel. It you don't get it the first time (I didn't) just put the funnel back in the water and press a little further down on the wine bottle next time. You should be able to just barely slip the funnel over the airbox extension- be sure to work it far enough down to cover both of the holes on the airbox with the funnel. as it cools, it will form a natural air tight seal (for all intents and purposes) i didn't bother to seal it. let it cool, and/or use cool water to speed up cooling.
step 6- clean and dry before intsalling
be sure to clean the air/box and funnel thuroughly before reinstalling. i just used warm water. dry with (paper) towels and let air dry.
step 7- Reinstall the airbox
Reinstallation was just reversal of removal. Again, be careful, if you had to move the wire before, that you keep it out of the way and put it back in the holder. The only change from removal was that i had to deform the funnel slightly, while inserting the airbox, to allow it to clear the plastic cap on the back of the headlight. Since the funnel is overall about 1-2 inches shorter than the snorkle, i wasn't worried about clearance issues and never saw fit to remove the grill or headlight.
Good luck
chris
'94 900SET 95k
'87 900 turbo -RIP
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